Regan Brown
Electric vehicles (EVs) are more environmentally friendly, longer-lasting, and cost-effective than fuel-powered cars. While purchasing an electric car can be expensive, converting a fuel-powered car to electric is a more affordable option. The conversion process involves replacing the internal combustion engine, transmission, gas tank, and exhaust system with an electric motor, controller, and EV battery. This requires significant mechanical and electrical expertise, so most people hire a company or purchase a conversion kit. The cost of conversion depends on various factors, including the type of battery and motor used, and the weight and body style of the donor car.
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What You'll Learn
Choosing a donor car
Weight
The ideal donor car is light and roomy. Heavier vehicles can restrict the range of the electric engine, as more power is needed to move them. Lighter cars and trucks extend the range of an electric car due to the lack of power needed to get it from point A to point B. A lightweight car (around 2,000 to 3,000 pounds curb weight) is recommended. Examples of suitable donor cars include the Volkswagen Rabbit, Honda Civic, Nissan Sentra, Ford Escort, or a light pickup truck.
Battery Room
Electric vehicles require a lot of room for batteries. The battery bank will typically be placed in the trunk or under the seats, so this area should be adequately spacious. The number of batteries needed will depend on the power system you will be using (48, 96, or 144 volts). The extra weight of the battery can range from 240 to 720 lbs.
Solid Chassis
Research the vehicle you are considering. Avoid cars with a history of chassis problems. Look for a vehicle with minimum body roll and adequate suspension. Check the entire vehicle for rust and ensure that the frame is not bent.
Condition
The donor car should be in good condition. Check that all the lights, windshield wipers, windows, doors, radio, electric mirrors, and seats are working as expected. If the car runs, that is a plus, but it is not necessary as you will be replacing the engine. However, ensure that the parts you are keeping, such as the brakes, are in good working order.
Two-Wheel Drive
A two-wheel-drive car is preferable because it can have its transmission taken out and will still operate fine as an electric vehicle, as long as the motor can produce low RPM output and reversing polarity to go backward.
Electrical Gadgets
Consider choosing a donor car without too many electrical gadgets such as power steering and air conditioning. This type of equipment will require additional power to work, which means you may need to build a separate power unit.
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Removing the engine, fuel tank, gearbox, etc
To begin the process of converting your fuel car to electric, you will need to remove the engine, fuel tank, gearbox, and other components of the gasoline internal combustion system. This step is crucial as it creates a clean slate for the electric conversion. Here is a detailed guide to help you through the process:
Removing the Engine and Transmission
Start by disassembling major components connected to the engine. This includes hoses, fuel lines, and wiring harnesses. You may need to remove the harness from the ECU inside the car, as per the vehicle's manual. Next, locate and loosen the front mount bolts and the transmission mount bolts. You can then lift the engine assembly out of the car, using a combination of pulleys and clotheslines, or chains and seat belts for stability.
Removing the Fuel Tank and Other Components
The fuel tank, exhaust, muffler, engine starter, radiator, coolant tank, and fuel filter will also need to be removed. Be very careful during this process to avoid any mess or damage to the vehicle. It is recommended to drain the fuel tank before attempting to remove it.
Removing the Gearbox
To remove the gearbox, or transmission, first find a flat, dry place to work. Remove the negative battery cable from the terminal post on the battery. Twist the gear shifter handle or knob counterclockwise and remove it. Some vehicles have a shifter trim plate or console, which must also be removed. Jack up your vehicle and place it securely on jack stands. Disconnect any electrical wire harnesses or other wires attached to the gearbox, including the speedometer cable. Finally, place a transmission jack directly under the transmission and loosen the bolts holding it in place. Once the bolts are removed, carefully lower the transmission out of the vehicle.
Remember to be cautious during this process and only proceed if you are confident in your abilities. It is important to note that removing these components can be complex and may require additional tools and knowledge. Always refer to your vehicle's manual for specific instructions and safety precautions.
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Installing an electric motor and batteries
The first step in the process is to remove all internal combustion engine (ICE) components, including the engine, fuel tank, muffler, exhaust system, starter, and radiator. This step is important as it creates space for the new electric components and reduces the weight of the car, making it easier to handle and more energy-efficient.
The next step is to select an electric motor that suits your performance requirements. The motor size is determined by the vehicle's dimensions and weight, as well as your desired level of performance. A more powerful motor will provide better acceleration and an extended range but will also increase the cost. The electric motor will be connected to the transmission system to power the car. This can be done through a coupler, such as a "Lovejoy"-style connector, which creates a mechanical connection between the motor and the transmission shaft.
The battery pack is another critical component of the conversion. The number and size of batteries required will depend on the type of vehicle and the amount of installation space available. Batteries provide power to the electric motor and determine the range of the vehicle. On average, a converted electric vehicle can achieve a range of 60 to 100 miles on a full charge, with a top speed of 50 to 90 mph. It is important to consider the weight distribution of the batteries to optimize handling and performance.
In addition to the motor and batteries, a power controller is necessary to regulate the flow of electricity between the battery and the motor. A charging system is also required to recharge the batteries through an electrical outlet. The cost of batteries and installation can range from $1,000 to $3,000, depending on the type and number of batteries chosen.
Converting a fuel car to electric power offers significant benefits, including reduced environmental impact, lower fuel and maintenance costs, improved performance, and increased vehicle value.
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The cost of conversion
The cost of converting a fuel car to electric varies depending on several factors, including the make and model of the vehicle, the complexity of the conversion process, and the choice of conversion kit.
Conversion kits typically include an electric motor, controller, battery pack, charging system, and other necessary components. The cost of these kits can range from a few thousand dollars to over a hundred thousand dollars. For example, Electric Classic Cars offers conversion kits for classics built from the 1950s to the early '80s, with prices ranging from £30,000 to £100,000. Lunaz, on the other hand, specializes in converting luxury classics such as Aston Martins and Rolls-Royces, with prices starting at £420,000.
The type of conversion kit chosen, whether premium or budget, also affects the cost. Premium kits offer advanced features and higher-quality components, while budget kits provide basic functionality at a lower price. Additionally, the vehicle's weight is a significant factor, as more power is required to propel heavier vehicles.
The cost of parts for a conversion is estimated to be around $6,000, with batteries and installation costing an additional $1,000 to $3,000. A more expensive retrofit could cost $20,000 or more. The price of a DIY kit installed by a qualified mechanic is roughly £15,000, while conversions by specialists usually start at around £30,000.
It is worth noting that the benefits of converting to electric include lower operating costs, reduced maintenance, and environmental sustainability. Electric vehicles are more efficient, require minimal maintenance, and produce zero tailpipe emissions, contributing to a cleaner and more sustainable energy ecosystem.
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The environmental impact
Electric vehicles (EVs) have a positive environmental impact as they improve fuel economy, lower fuel costs, and reduce emissions. They require no gasoline and less maintenance, and have better resale values. They are also more reliable overall since they have fewer parts, and most of these are solid-state electronics with no moving parts.
EVs produce zero tailpipe emissions, and even plug-in hybrid electric vehicles (PHEVs) produce no tailpipe emissions when operating in all-electric mode. They are more energy-efficient than gasoline vehicles, using approximately 87-91% of the energy from the battery and regenerative braking to propel the vehicle. In contrast, gasoline vehicles only convert about 16-25% of the energy from gasoline into movement.
However, the environmental benefits of EVs are dependent on the energy sources used to charge them. In countries that rely heavily on burning coal for energy, EVs may have a similar carbon footprint to gasoline vehicles. Nevertheless, as renewable energy sources like wind and solar become more prevalent, the total GHGs associated with EVs will decrease.
Converting a gas-powered car to electric can also have environmental benefits. Firstly, it gives new life to the body of an older car, reducing the waste created when cars reach the end of their life cycle. Secondly, it is a cheaper way to drive a zero-emissions vehicle, helping to reduce one's carbon footprint. Finally, converting a car to electric can be done for a lower cost than buying a new electric vehicle, and one can even make some of the conversion costs back by selling the parts that are no longer needed, like the engine and fuel tank.
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Frequently asked questions
The conversion process can take three months or longer, with conversion companies often taking six months to complete the job. The time taken depends on the complexity of the conversion.
The cost of converting a fuel car to electric depends on the type of conversion. Basic conversions can start at $6,000 for parts, while more advanced conversions can cost upwards of $9,000. Batteries and installation can cost between $1,000 to $3,000.
Electric cars are more environmentally friendly, have better acceleration, require less maintenance, and are cheaper to operate in the long run due to lower fuel and maintenance costs.
