Electric vehicle conversion
Encyclopedia
An electric vehicle conversion is the modification of a conventional internal combustion engine vehicle (ICEV) to electric
propulsion, creating an all-electric or plug-in hybrid electric vehicle.
However, currently the relatively small power generated by solar cells means that the other components in the system must be special to compensate for this.
For example, the body of even a small conventional car converted to electric is still rather too heavy to be able to be matched with an electric system that is solely or primarily charged by solar power.
Thus, it is usually more practical to create a solar-powered electric vehicle from scratch or specially made parts.
.
A two-stage vehicle is a vehicle that has been built by two separate manufacturers. The result is a standard, complete vehicle. In this process, vehicles may be converted by a manufacturer (as was done by Ford Motor Company
to create the Ford Ranger EV
). Alternatively, in a process known as "third-party (power)trainization
", an independent converter will purchase new vehicle glider
s (vehicles without a motor or related equipment) and then perform the conversion, to offer a two-stage vehicle.
In some countries, the user can choose to buy a converted vehicle of any model in the automaker dealerships
only paying the cost of the batteries and motor, with no installation costs (it is called pre-conversion or previous conversion).
, aftermarket kits and vehicle components.
An electric bicycle
is a conventional bicycle that has been fitted with an electric motor. Converting an existing bicycle by retrofitting it with a "conversion kit" is the simplest and least expensive electric vehicle conversion option. Most often electric bicycles or "e-bikes" are powered by rechargeable batteries however some experimental electric bicycles run directly on or recharge their batteries via solar panels, fuel cells, gas generators or other alternative energy sources. Some experimenters have even used super capacitors to store energy. Using an on-board generator may impact the legal jurisdictional definition of an electric bicycle. A few types of electric bicycles are able to re-capture a small amount of energy from braking and can re-charge the batteries while braking or traveling down hills (regenerative braking).
Some electric bikes have features where the motor can move the bicycle by itself (immediate start) if the rider chooses not to pedal with a button or throttle controller, while others require the rider to pedal at all times (pedal assist). This latter type may in some jurisdictions allow the vehicle to be used on bicycle trails that otherwise prohibit motorized vehicles of any kind (See motorized bicycle
).
Many battery technologies are available for powering electric bikes. The most common and least expensive battery technology is sealed lead acid but LiFePO4
is fast becoming the battery of choice for the e-bike.
Converting one's bike to electric with a conversion kit is an easy and affordable solution for most people interested in learning more about electric vehicle conversion. E-Bikes are the cleanest, most affordable and most energy efficient form of transportation on the planet.
There may be some problems with the warranty however on the original bicycle being converted, if an electric bike conversion kit is added.
Owing to its light weight and efficiency, a light vehicle can make an excellent choice, particularly if care is taken in component selection and placement. It is possible to obtain conversion kits for some popular light vehicles, most notably the rear motor, rear drive Volkswagen Beetle
, its Type 3 evolution, and its successor, the front motor/drive VW Rabbit.
By converting a light vehicle it is possible to use a smaller motor, which both weighs and costs less than a larger motor. A lighter overall vehicle weight will reduce power consumption in start-and-stop traffic and increase range in many practical driving conditions.
. In this conversion, the back seat was retained, and there is still enough room to sink nine flooded lead-acid batteries low in the trunk where the spare tire was located, as well as another nine batteries under the hood. Another example is a 1987 Mitsubishi Tredia
where the rear batteries have been raised above the trunk floorspace, sealed, and externally vented. With suspension modifications, increasing shock length & spring rating, the car must still be below GVWR, even with the driver and passengers. Exceeding the total design weight of the vehicle would be illegal in some states, and might result in cancellation by an insurance company.
There is an effort by several engineers in California to make the Toyota Prius
a "Plug-In Hybrid Electric Vehicle," or PHEV, whereby the first 40 miles are driven by all-electric power, then the gas engine comes on to re-charge the batteries, only if the commute is further than 40 mi. If it's less, one can just plug it into the utility grid to re-charge the batteries. The process is done by removing the nickel-metal hydride batteries, and installing different batteries, and a different battery management system.
Since 30 April 2009, the Electric Car Corporation
have been selling the Citroën C1 ev'ie
, an all-electric conversion from the Citroën C1
.
s are generally considered to be poor candidates for EV conversion. As the suspension and tires are already operating close to the maximum permissible , it may be necessary to make substantial modifications in these areas. It may be easier to obtain upgraded suspension components for some smaller vehicles, if these are also typically used for sports racing (particularly autocross
). Starting with a heavy vehicle and adding batteries will result in poor performance in acceleration, handling, braking, and economy of operation.
One of possibilities is using the body of Audi's D2 platform A8 (1994–2003) Audi A8
or sports sedan S8 (1998-2003 or older European market models where the German model weights 1730 kg) Audi S8
both of which are all aluminium
monocoque
"Audi Space Frame
" vehicle, which helped to significantly reduce weight without being any less rigid.
The 1969-1976 Porsche 914
is one of the more successful sports car conversions, as well as being one of the most popular. Once converted, it boasts better performance in range, acceleration and top speed than most other vehicles. Also, its low acquisition costs contributes to its popularity as a conversion candidate. Some manufacturers of conversion kits have made a kit specific to the 914.
Another popular sports car used for conversion is the 1984-1989 Toyota MR2
. Reasons for its popularity are low weight before conversion, low cost to purchase the car, and available locations within the car to place the large batteries that most people use (lead-acid and its derivative technologies). The later MR2 body style (Mark 2) does not seem as popular, and as of March 2008, there is only one known conversion.
The Bradley
GT II as well as other VW-based kit car
s are very popular conversion candidates due to their being inexpensive, extensive support groups as well as their simple sports car design. Availability of conversion kits for these cars are quite prevalent with commercial retail establishments that specialize in EV conversions.
version. While a number of suitable vehicles are available in pre-2002 models, the modern evolution of this type has become taller, heavier, bulkier and less efficient, and their excessive height makes under-bed battery placement essential to keep the center of gravity low enough for stability on curves.
EV converted by Wilde Evolutions, and the 1988 Jeep Cherokee
EV converted by Nick Viera.
es (this is,without trolleys and wires) have involved limited production of very expensive fuel cell vehicle
s.
The most economically effective development in this area involves the creation of hybrid electric buses (mainly plug-in hybrids), well suited to this application owing to frequent stops and starts and effective energy recovery and release in this cycle.
Another solution is the conversion to battery electric buses that follow the principle of replacing (discharged batteries)
instead of recharging.
vehicle. The leading vehicle in this field is the "Maniac Mazda" a Mazda RX-7 sports car converted from rotary engine to electric by Roderick Wilde. This vehicle can outrun Dodge Viper and Ferrari sports cars in quarter mile drag races.
electric vehicle's most obvious competitive disadvantage, the weight penalty of batteries compared to gasoline.
s".
Even more specialized than the drag racer, this is intended to obtain high speeds on long, straight, and flat raceways, such as the dry lake beds found in locations such as the Bonneville Salt Flats.
, particularly any type of endurance racing, is one of the greatest challenges for EV's. Pound per pound, gasoline contains far more energy than even the most advanced of current batteries. An electric vehicle must be heavier or more efficient to run the same distance as its gasoline competitor. Endurance racing strategies include battery packs that can be changed quickly and "Dump charging
"
this can result in a unique vehicle. It is especially suitable for the construction of a lightweight vehicle that can offer exceptional performance. Many VW-based kit car companies have tube chassis ready to start with.
A glider kit includes all components of a vehicle except the power train.
may not be suitable for on road use. Applications include electric vehicle show demonstrations, parades, parade floats, float towing, and eclectic off-road gatherings such as Burning Man
.
This vehicle is ideal for the beach
(where not prohibited) and to promote tourist places but will usually require trailering to its operating site.
Above: Bob Schneeveis demonstrates his Silver Sofa.
Registration procedures will vary by state and will usually be more difficult (even bizarre) in states with strict emissions requirements (even though a plug-in only conversion will be a zero emission vehicle). Arguing with DMV staff is typically futile in all jurisdictions, but there may be appeal procedures available but whose availability may not be openly publicized.
On the other hand, changing the registration allows a conversion to qualify for tax incentives available in some states, such as Oregon, for either the vehicle, the charging system, or both.
This falls into two categories ; First, if the vehicle is built from new frame components and possibly some salvage parts, (i.e., it has never been a previously titled motorcar previously, but it has brakes or axles that were obtained used/rebuilt.) In California if you "Create' a car from scratch and want to register and title it with DMV , you need to go through the "Specially Constructed Vehicle Emission Control Program or SPCNS for short, this is also called California "SB100" program. SPCNS Sequence Numbers are limited at 500 units per calendar year.
The SPCNS / SB100 Program is intended / meant for emission control for home built kit cars or hot rods. as of November 2009, California DMV has no pathway for a home builder to create a electric car without subscribing to the current SPCNS program, which was originally meant for historic replicas and gasoline powered cars.
Limitation: California SB100/SPCNS is limited to 500 cars per year. All 500 "sequence numbers" are consumed within minutes on the first DMV business day of the calendar year. SPCNS registration requires a significant paper trail on all frame/body/components, this is to assure stolen parts are not used in construction. Additionally, since registration fees and vehicle sales tax are generated from these figures, their requirement aids in revenue collection for each SPCNS number issued.
OFF-ROAD vehicles; "Kei car
"-class trucks, four wheel sport "dirt" vehicles, and other utility vehicles imported and sold for off-road
use only; The electric conversion of a vehicle that was previously not certified for "On-Road" does not enable it to be registered for "On-Road" use with the conversion to electric power only. An example; certain subcompacts cannot qualify for registration except if a custom body or frame is installed to have the vehicle confirm to "On-Road" brake/light/safety standards.
As all originally ICE street-legal automobiles and light trucks built after 1975 must pass a smog test (including a "visual inspection"), a conversion of such a late model vehicle must be registered as an electric powered only vehicle and thus exempt. Otherwise, it would fail the required smog test, not for producing pollution, but for being altered from its original configuration and so failing the visual inspection portion of the test. Since 1975 and earlier vehicles are not currently tested for any smog compliance, it would be possible to convert them to electric power with little or no paperwork/certification issues.
It is no more simple if the vehicle is registered with current tags in California and may even be more difficult. Under new 2008 regulations for converted ICE vehicles a multi-step process is required. First, an appointment is made by telephone with a "Smog Referee". A meeting with the vehicle to be registered will typically be at a local community college with an extensive automotive shop program. The referee will inspect and certify that the vehicle is both smog exempt and that it qualifies for an "E" power code (electric-only). The next step requires real-time coordination between a cooperative clerk at the local California Department of Motor Vehicles (DMV) office and an appropriate clerk at the Sacramento
office. (These procedures are in place to inhibit fraudulent registration of ICE vehicles as Electric in order to avoid smog inspections.) If the computer terminals are not operated in a coordinated manner the registration propulsion code will default to "Q" (hybrid vehicle
) which is not exempt from smog inspection and the conversion will always fail such an inspection. Unfortunately, once the computer has defaulted to the "Q" code it is necessary to re-engage the Smog Referee to obtain a new prospective "E" code. The ability to successfully register as an electric vehicle is highly dependent upon the cooperation of the staff at the local office, their experience with registering electric vehicles, their ability to coordinate with Sacramento, and their interest in assisting you. Some offices will be much more accommodating than others. Multiple trips to the DMV office and the Referee are typically required.
Since no fuel or recharging taxes are collected the revenue that would otherwise be lost to the state is made up for with a substantial weight fee specific to electric vehicles registered for commercial use (no weight charges are added for noncommercial vehicles). While light ICE vehicles are taxed on a refined and progressive grading scheme, electric vehicles with commercial licenses are grouped into only a few broad categories, with the result that even a modest and lightweight commercially registered EV will pay the same tax as will a much heaver (up to 6000 lbs) EV. If an open-bed pickup truck (as opposed to a panel truck) is converted, the only way to register it as a non-commercial vehicle (and so avoid the weight fees) is to permanently install a camper shell
(not a bed cover), which need not project above the truck cab nor include any other "camping" equipment. (This can be inconvenient if access to an in-bed battery box is required.) In California, one advantage of a commercial license is the ability to park in yellow zones, but only for short term pick-up and delivery.
Electricity
Electricity is a general term encompassing a variety of phenomena resulting from the presence and flow of electric charge. These include many easily recognizable phenomena, such as lightning, static electricity, and the flow of electrical current in an electrical wire...
propulsion, creating an all-electric or plug-in hybrid electric vehicle.
Elements of a conversion
- Almost any vehicle can be converted to electric. Many people prefer to pick a vehicle that is light and aerodynamic in order to maximize distance traveled per battery charge. There must also be adequate room and load capacity for batteries.
- The battery packBattery packA battery pack is a set of any number of identical batteries or individual battery cells. They may be configured in a series, parallel or a mixture of both to deliver the desired voltage, capacity, or power density...
, which provides a source of electrical power. The most commonly available and affordable batteries are lead-acidLead-acid batteryLead–acid batteries, invented in 1859 by French physicist Gaston Planté, are the oldest type of rechargeable battery. Despite having a very low energy-to-weight ratio and a low energy-to-volume ratio, their ability to supply high surge currents means that the cells maintain a relatively large...
flooded type. Next are the AGM (Absorption Glass Mat) sealed maintenance free batteries, a little more powerful and expensive. Then there are the more exotic batteries like Ni-MH and Li-ion; more difficult to find but light and longer lasting, maintenance free, and much more expensive. The new lithium batteries are showing some promise for EVs in the near future. - The charger which restores energy to the batteries (which may be mounted within the vehicle or at a special charging station at some fixed location)
- The power controllerMotor controllerA motor controller is a device or group of devices that serves to govern in some predetermined manner the performance of an electric motor. A motor controller might include a manual or automatic means for starting and stopping the motor, selecting forward or reverse rotation, selecting and...
, which regulates the flow of energy between the batteryBattery (electricity)An electrical battery is one or more electrochemical cells that convert stored chemical energy into electrical energy. Since the invention of the first battery in 1800 by Alessandro Volta and especially since the technically improved Daniell cell in 1836, batteries have become a common power...
and the electric motorElectric motorAn electric motor converts electrical energy into mechanical energy.Most electric motors operate through the interaction of magnetic fields and current-carrying conductors to generate force...
(s), controlled by an electronic throttle. - One or more electric motors and their mechanical attachment to the driveline
- Power conductorCableA cable is two or more wires running side by side and bonded, twisted or braided together to form a single assembly. In mechanics cables, otherwise known as wire ropes, are used for lifting, hauling and towing or conveying force through tension. In electrical engineering cables are used to carry...
s connecting the battery, controller, and motor(s) - Accessory equipment to power auxiliary equipment such as power brakes and heating system
- Control circuitry and equipment to allow control and interlocking of the various components
- Instrumentation specific to the operation and maintenance of the conversion
Solar power
Solar cells could be used to power a vehicle converted to electric.However, currently the relatively small power generated by solar cells means that the other components in the system must be special to compensate for this.
For example, the body of even a small conventional car converted to electric is still rather too heavy to be able to be matched with an electric system that is solely or primarily charged by solar power.
Thus, it is usually more practical to create a solar-powered electric vehicle from scratch or specially made parts.
Conversion process
Most conversions in North America are performed by hobbyists who typically will convert a well used vehicle with a non-functioning engine, since such defective vehicles can be quite inexpensive to purchase. Other hobbyists with larger budgets may prefer to convert a later model vehicle, or a vehicle of a particular type. In some cases the vehicle itself may be built by the converter, or assembled from a kit carKit car
A kit car, also known as a "component car", is an automobile that is available as a set of parts that a manufacturer sells and the buyer then either assembles into a car themselves, or retains a third party to do part or all of the work on their behalf...
.
A two-stage vehicle is a vehicle that has been built by two separate manufacturers. The result is a standard, complete vehicle. In this process, vehicles may be converted by a manufacturer (as was done by Ford Motor Company
Ford Motor Company
Ford Motor Company is an American multinational automaker based in Dearborn, Michigan, a suburb of Detroit. The automaker was founded by Henry Ford and incorporated on June 16, 1903. In addition to the Ford and Lincoln brands, Ford also owns a small stake in Mazda in Japan and Aston Martin in the UK...
to create the Ford Ranger EV
Ford Ranger EV
The Ford Ranger EV is a battery electric vehicle produced by Ford Motor Company. It was produced starting in the 1998 model year through 2002 and is no longer in production. It is built upon a light truck chassis used in the Ford Ranger. A few vehicles with lead-acid batteries were sold, but most...
). Alternatively, in a process known as "third-party (power)trainization
Powertrain
In a motor vehicle, the term powertrain or powerplant refers to the group of components that generate power and deliver it to the road surface, water, or air. This includes the engine, transmission, drive shafts, differentials, and the final drive...
", an independent converter will purchase new vehicle glider
Vehicle glider
In automobiles, a glider is a vehicle without a powertrain . It is generally a brand new car, but a second-hand car can also be used...
s (vehicles without a motor or related equipment) and then perform the conversion, to offer a two-stage vehicle.
In some countries, the user can choose to buy a converted vehicle of any model in the automaker dealerships
Car dealership
A car dealership or vehicle local distribution is a business that sells new or used cars at the retail level, based on a dealership contract with an automaker or its sales subsidiary. It employs automobile salespeople to do the selling...
only paying the cost of the batteries and motor, with no installation costs (it is called pre-conversion or previous conversion).
Industry
The electric vehicle conversion industry has grown to include conversion car garagesGarage (house)
A residential garage is part of a home, or an associated building, designed or used for storing a vehicle or vehicles. In some places the term is used synonymously with "carport", though that term normally describes a structure that is not completely enclosed.- British residential garages:Those...
, aftermarket kits and vehicle components.
Electric bicycle
Electric bicycle
An electric bicycle, also known as an e-bike, is a bicycle with an electric motor used to power the vehicle. Electric bicycles typically cost between and , use rechargeable batteries and can travel up to...
is a conventional bicycle that has been fitted with an electric motor. Converting an existing bicycle by retrofitting it with a "conversion kit" is the simplest and least expensive electric vehicle conversion option. Most often electric bicycles or "e-bikes" are powered by rechargeable batteries however some experimental electric bicycles run directly on or recharge their batteries via solar panels, fuel cells, gas generators or other alternative energy sources. Some experimenters have even used super capacitors to store energy. Using an on-board generator may impact the legal jurisdictional definition of an electric bicycle. A few types of electric bicycles are able to re-capture a small amount of energy from braking and can re-charge the batteries while braking or traveling down hills (regenerative braking).
Some electric bikes have features where the motor can move the bicycle by itself (immediate start) if the rider chooses not to pedal with a button or throttle controller, while others require the rider to pedal at all times (pedal assist). This latter type may in some jurisdictions allow the vehicle to be used on bicycle trails that otherwise prohibit motorized vehicles of any kind (See motorized bicycle
Motorized bicycle
A motorized bicycle, motorbike, cyclemotor, or vélomoteur is a bicycle with an attached motor and transmission used either to power the vehicle unassisted, or to assist with pedaling. Since it always retains both pedals and a discrete connected drive for rider-powered propulsion, the motorized...
).
Many battery technologies are available for powering electric bikes. The most common and least expensive battery technology is sealed lead acid but LiFePO4
Lithium iron phosphate battery
The lithium iron phosphate battery, also called LFP battery, is a type of rechargeable battery, specifically a lithium-ion battery, which uses LiFePO4 as a cathode material.-History:...
is fast becoming the battery of choice for the e-bike.
Converting one's bike to electric with a conversion kit is an easy and affordable solution for most people interested in learning more about electric vehicle conversion. E-Bikes are the cleanest, most affordable and most energy efficient form of transportation on the planet.
There may be some problems with the warranty however on the original bicycle being converted, if an electric bike conversion kit is added.
Electric Two-Wheelers (E-Bikes, Motorcycles and Scooters)
Low-speed Scooters are not typically suitable for on-the-road use. These may be configured for either standing or sitting use. Some local laws apply bicycle laws to scooters, such as helmet and pedestrian right-of-way considerations.Economy coupe
Volkswagen Beetle
The Volkswagen Type 1, widely known as the Volkswagen Beetle or Volkswagen Bug, is an economy car produced by the German auto maker Volkswagen from 1938 until 2003...
, its Type 3 evolution, and its successor, the front motor/drive VW Rabbit.
By converting a light vehicle it is possible to use a smaller motor, which both weighs and costs less than a larger motor. A lighter overall vehicle weight will reduce power consumption in start-and-stop traffic and increase range in many practical driving conditions.
Compact sedan or coupe
A compact sedan may be a better choice than a subcompact owing to better load capacity and more room for battery placement. Some commercial EV Conversions use vehicles in this size range. One example is a 1992 Honda CivicHonda Civic
The Honda Civic is a line of subcompact and subsequently compact cars made and manufactured by Honda. The Civic, along with the Accord and Prelude, comprised Honda's vehicles sold in North America until the 1990s, when the model lineup was expanded...
. In this conversion, the back seat was retained, and there is still enough room to sink nine flooded lead-acid batteries low in the trunk where the spare tire was located, as well as another nine batteries under the hood. Another example is a 1987 Mitsubishi Tredia
Mitsubishi Tredia
The Mitsubishi Tredia was a subcompact sedan built by Mitsubishi Motors from 1982 to 1990. Its name is supposedly derived from Mitsubishi's "Three Diamonds" logo...
where the rear batteries have been raised above the trunk floorspace, sealed, and externally vented. With suspension modifications, increasing shock length & spring rating, the car must still be below GVWR, even with the driver and passengers. Exceeding the total design weight of the vehicle would be illegal in some states, and might result in cancellation by an insurance company.
There is an effort by several engineers in California to make the Toyota Prius
Toyota Prius
The Toyota Prius is a full hybrid electric mid-size hatchback, formerly a compact sedan developed and manufactured by the Toyota Motor Corporation...
a "Plug-In Hybrid Electric Vehicle," or PHEV, whereby the first 40 miles are driven by all-electric power, then the gas engine comes on to re-charge the batteries, only if the commute is further than 40 mi. If it's less, one can just plug it into the utility grid to re-charge the batteries. The process is done by removing the nickel-metal hydride batteries, and installing different batteries, and a different battery management system.
Since 30 April 2009, the Electric Car Corporation
Electric Car Corporation
The Electric Car Corporation plc is an electric car manufacturer and dealer based in Mayfair, London with an assembly plant in Flitwick, Bedfordshire. It makes and sells the Citroën C1 ev'ie, an electric car adapted from the Citroën C1...
have been selling the Citroën C1 ev'ie
Citroën C1 ev'ie
The Citroën C1 ev'ie is an electric car conversion from a standard Citroën C1 by the Electric Car Corporation. The model was first released on 30 April 2009, with a 2010 list price of £19,860 this makes the C1 ev'ie a competitively priced electric car.The Citroën C1 ev'ie's body and fittings are...
, an all-electric conversion from the Citroën C1
Citroën C1
The Citroën C1 is a city car produced by the French manufacturer Citroën since 2005.The C1 was developed as part of the B-Zero project by PSA Peugeot Citroën in a joint-venture with Toyota. The Peugeot 107 is identical to the C1 other than the front bumper and front and rear lights, while the...
.
Full-size sedan
Full-size sedans and minivanMinivan
Minivan is a type of van designed for personal use. Minivans are typically either two-box or one box designs for maximum interior volume – and are taller than a sedan, hatchback, or a station wagon....
s are generally considered to be poor candidates for EV conversion. As the suspension and tires are already operating close to the maximum permissible , it may be necessary to make substantial modifications in these areas. It may be easier to obtain upgraded suspension components for some smaller vehicles, if these are also typically used for sports racing (particularly autocross
Autocross
Autocross is a form of motorsports that emphasizes safe competition and active participation. An autocross is a timed competition where drivers navigate one at a time through a defined course on either sealed or unsealed surfaces...
). Starting with a heavy vehicle and adding batteries will result in poor performance in acceleration, handling, braking, and economy of operation.
One of possibilities is using the body of Audi's D2 platform A8 (1994–2003) Audi A8
Audi A8
The Audi A8 is a four-door, full-size, luxury sedan car manufactured and marketed by the German automaker Audi since 1994. Succeeding the Audi V8, the A8 has been offered with front wheel drive or permanent four-wheel drive, with multitronic or tiptronic automatic transmissions — and in short- and...
or sports sedan S8 (1998-2003 or older European market models where the German model weights 1730 kg) Audi S8
Audi S8
The Audi S8 quattro is a high-performance version of the German luxury automaker Audi's flagship car, the full-size Audi A8. The S8 is produced at Audi's Neckarsulm 'aluminium plant', and it was introduced in September 1994...
both of which are all aluminium
Aluminium
Aluminium or aluminum is a silvery white member of the boron group of chemical elements. It has the symbol Al, and its atomic number is 13. It is not soluble in water under normal circumstances....
monocoque
Monocoque
Monocoque is a construction technique that supports structural load by using an object's external skin, as opposed to using an internal frame or truss that is then covered with a non-load-bearing skin or coachwork...
"Audi Space Frame
Space frame
A space frame or space structure is a truss-like, lightweight rigid structure constructed from interlocking struts in a geometric pattern. Space frames can be used to span large areas with few interior supports...
" vehicle, which helped to significantly reduce weight without being any less rigid.
Sports car
For a person interested in sports car performance and appearance, the creation of a satisfying conversion will likely lead to a number of difficulties in such details as battery disposition, as such vehicles generally have available space distributed in small volumes around the vehicle. This leads to complexity in securing and wiring batteries. These vehicles can offer stunning performance in the lower speed ranges owing to light weight and rear wheel drive, and may also offer good range due to their superior aerodynamics.The 1969-1976 Porsche 914
Porsche 914
The Porsche 914 or VW-Porsche 914 is a mid-engined, targa-topped two-seat roadster designed, manufactured and marketed collaboratively by Volkswagen and Porsche from 1969 to 1976.- Development :...
is one of the more successful sports car conversions, as well as being one of the most popular. Once converted, it boasts better performance in range, acceleration and top speed than most other vehicles. Also, its low acquisition costs contributes to its popularity as a conversion candidate. Some manufacturers of conversion kits have made a kit specific to the 914.
Another popular sports car used for conversion is the 1984-1989 Toyota MR2
Toyota MR2
The Toyota MR2 is a two-seat, mid-engined, rear wheel drive sports car produced by Central Motors, a part of Toyota, from 1984 until July 2007 when production stopped in Japan...
. Reasons for its popularity are low weight before conversion, low cost to purchase the car, and available locations within the car to place the large batteries that most people use (lead-acid and its derivative technologies). The later MR2 body style (Mark 2) does not seem as popular, and as of March 2008, there is only one known conversion.
The Bradley
Bradley Automotive
Bradley Automotive was created by Gary Courneya and David Bradley Fuller and sold the Bradley line of kit cars from their facility in Plymouth, Minnesota....
GT II as well as other VW-based kit car
Kit car
A kit car, also known as a "component car", is an automobile that is available as a set of parts that a manufacturer sells and the buyer then either assembles into a car themselves, or retains a third party to do part or all of the work on their behalf...
s are very popular conversion candidates due to their being inexpensive, extensive support groups as well as their simple sports car design. Availability of conversion kits for these cars are quite prevalent with commercial retail establishments that specialize in EV conversions.
Light truck
Light trucks are especially suitable for hobbyist conversion because it is easy to locate batteries remote from the passenger compartment and there is a good load handling capacity for the use of heavy batteries such as the flooded lead-acid batteries commonly used in golf carts. Light trucks also offer substantial utility in use simply because they are trucks. Even if a portion of the weight capacity is removed by the presence of batteries within or below the cargo bed, much or all of the spatial utility remains. A light truck is highly recommended as a first conversion effort because of the simplicity of component layout. With proper battery placement the stability of a late production truck can be improved over the ICEInternal combustion engine
The internal combustion engine is an engine in which the combustion of a fuel occurs with an oxidizer in a combustion chamber. In an internal combustion engine, the expansion of the high-temperature and high -pressure gases produced by combustion apply direct force to some component of the engine...
version. While a number of suitable vehicles are available in pre-2002 models, the modern evolution of this type has become taller, heavier, bulkier and less efficient, and their excessive height makes under-bed battery placement essential to keep the center of gravity low enough for stability on curves.
Other trucks - full size and most SUVs
These are rarely converted due to their excessive weight, and aerodynamic inefficiencies. To make the situation worse, many modern trucks and SUVs continue to get bulkier, heavier, and their high stance means the height of the center of gravity leads to instability while making high speed turns, a distinct disadvantage if there is not enough room between the frame rails to enable low battery mounting. As a direct result, the payload carrying capacity and thus the GVWR of the vehicles goes down. Such a trait is not desirable because it limits the weight of the battery pack that can be carried, limiting the maximum battery-to-vehicle weight ratio that could be achieved for the vehicle when converted to an EV. (Such considerations are important due to price, weight, and performance limitations of current battery technologies.) For a given battery type, reducing the battery-to-vehicle weight ratio always results in reduced vehicle range per charge. However, despite these mostly unavoidable limitations, several SUVs and larger trucks have been successfully converted to electric power by hobbyists. Some examples include the "Gone Postal" van converted to an EV racer by Roderick Wilde and Suckamps EV Racing, the Land RoverLand Rover
Land Rover is a British car manufacturer with its headquarters in Gaydon, Warwickshire, United Kingdom which specialises in four-wheel-drive vehicles. It is owned by the Indian company Tata Motors, forming part of their Jaguar Land Rover group...
EV converted by Wilde Evolutions, and the 1988 Jeep Cherokee
Jeep Cherokee (XJ)
The Jeep Cherokee is a unibody compact SUV. It shared the name of the original full-size SJ model, but without a body-on-frame chassis, it set the stage for the modern SUV. Its innovative appearance and sales popularity spawned important imitators as other automakers began to notice that this...
EV converted by Nick Viera.
Electric buses
The principal efforts in the development of autonomous electric busElectric bus
An electric bus is a bus powered by electricity.There are two main electric bus categories:* Non-autonomous electric buses:**The trolleybus is a type of electric bus powered by two overhead electric wires, with electricity being drawn from one wire and returned via the other wire, using two...
es (this is,without trolleys and wires) have involved limited production of very expensive fuel cell vehicle
Fuel cell vehicle
A Fuel cell vehicle or Fuel Cell Electric Vehicle is a type of hydrogen vehicle which uses a fuel cell to produce electricity, powering its on-board electric motor...
s.
The most economically effective development in this area involves the creation of hybrid electric buses (mainly plug-in hybrids), well suited to this application owing to frequent stops and starts and effective energy recovery and release in this cycle.
Another solution is the conversion to battery electric buses that follow the principle of replacing (discharged batteries)
Charging station
An electric vehicle charging station, also called EV charging station, electric recharging point, charging point and EVSE , is an element in an infrastructure that supplies electric energy for the recharging of electric vehicles, plug-in hybrid electric-gasoline vehicles) or semi-static and mobile...
instead of recharging.
Hotrod
While this type of vehicle is usually made to be a "street-legal" performance machine, it may also be developed for occasional use as a drag racingDrag racing
Drag racing is a competition in which specially prepared automobiles or motorcycles compete two at a time to be the first to cross a set finish line, from a standing start, in a straight line, over a measured distance, most commonly a ¼-mile straight track....
vehicle. The leading vehicle in this field is the "Maniac Mazda" a Mazda RX-7 sports car converted from rotary engine to electric by Roderick Wilde. This vehicle can outrun Dodge Viper and Ferrari sports cars in quarter mile drag races.
Autocross racer
EV's have proven successful in autocross competition. The electric motor's ability to deliver maximum torque at 0 RPM and a comparatively broad torque band provide good throttle response and allow running an autocross without any time lost to shifting gears. The short distance of the typical autocross requires less stored energy than most forms of motorsports. This minimizeselectric vehicle's most obvious competitive disadvantage, the weight penalty of batteries compared to gasoline.
Drag racer
Intended only for specialized straight line quarter mile (acceleration) racing this type of vehicle is used only "off road" at specialized "drag stripDrag strip
Drag strip may refer to:*Dragstrip, track used for drag racing*Drag Strip , Transformer character who is one of the Stunticons*Videocart-9: Drag Strip, drag racing videogame released in 1976-See also:*Dover Drag Strip...
s".
High speed straight line racer
- For an example of a straight line racer see Buckeye BulletBuckeye BulletThe Buckeye Bullet is the name of a series of student-built, alternative-fuel race cars created by The Ohio State University students led by Dr. Giorgio Rizzoni at the Center for Automotive Research...
Even more specialized than the drag racer, this is intended to obtain high speeds on long, straight, and flat raceways, such as the dry lake beds found in locations such as the Bonneville Salt Flats.
Closed circuit road racer
Closed Circuit Road racingRoad racing
Road racing is a general term for most forms of motor racing held on paved, purpose-built race tracks , as opposed to oval tracks and off-road racing...
, particularly any type of endurance racing, is one of the greatest challenges for EV's. Pound per pound, gasoline contains far more energy than even the most advanced of current batteries. An electric vehicle must be heavier or more efficient to run the same distance as its gasoline competitor. Endurance racing strategies include battery packs that can be changed quickly and "Dump charging
Dump charging
Dump charging is a method of charging a electric vehicle's battery pack at a higher rate than is possible with standard grid connections and battery chargers...
"
Custom chassis
Suitable for a builder who is capable of constructing a kit car, with good abilities and equipment in machining and weldingWelding
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material that cools to become a strong joint, with pressure sometimes...
this can result in a unique vehicle. It is especially suitable for the construction of a lightweight vehicle that can offer exceptional performance. Many VW-based kit car companies have tube chassis ready to start with.
A glider kit includes all components of a vehicle except the power train.
Novelty vehicle
A novelty vehicle or an electric powered art carArt car
An art car is a vehicle that has had its appearance modified as an act of personal artistic expression. Art cars are often driven and owned by their creators, who are sometimes referred to as "Cartists"....
may not be suitable for on road use. Applications include electric vehicle show demonstrations, parades, parade floats, float towing, and eclectic off-road gatherings such as Burning Man
Burning Man
Burning Man is a week-long annual event held in the Black Rock Desert in northern Nevada, in the United States. The event starts on the Monday before the American Labor Day holiday, and ends on the holiday itself. It takes its name from the ritual burning of a large wooden effigy on Saturday evening...
.
This vehicle is ideal for the beach
Beach
A beach is a geological landform along the shoreline of an ocean, sea, lake or river. It usually consists of loose particles which are often composed of rock, such as sand, gravel, shingle, pebbles or cobblestones...
(where not prohibited) and to promote tourist places but will usually require trailering to its operating site.
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Above: Bob Schneeveis demonstrates his Silver Sofa.
United States
The ease of registration will vary by state. Some states require safety inspections, usually to ensure body integrity in areas subject to severe corrosion from winter road de-icing materials. In any case, for general registration all functional safety equipment should be operating - turn signals, brake lights, headlights, horn, etc. The windshield should have no running cracks (small stone chips and "stars" may be acceptable if not in the driver's principal line of vision). If the vehicle has been reconstructed from a salvage vehicle (a vehicle whose registration has been forfeited) inspection may be more severe to ensure compliance and the legitimacy of sources of salvage components by presentation of proper purchase receipts.Registration procedures will vary by state and will usually be more difficult (even bizarre) in states with strict emissions requirements (even though a plug-in only conversion will be a zero emission vehicle). Arguing with DMV staff is typically futile in all jurisdictions, but there may be appeal procedures available but whose availability may not be openly publicized.
On the other hand, changing the registration allows a conversion to qualify for tax incentives available in some states, such as Oregon, for either the vehicle, the charging system, or both.
California (US) conversion registration and taxation
Registration of a converted existing, or newly self constructed electric vehicle in California is difficult.This falls into two categories ; First, if the vehicle is built from new frame components and possibly some salvage parts, (i.e., it has never been a previously titled motorcar previously, but it has brakes or axles that were obtained used/rebuilt.) In California if you "Create' a car from scratch and want to register and title it with DMV , you need to go through the "Specially Constructed Vehicle Emission Control Program or SPCNS for short, this is also called California "SB100" program. SPCNS Sequence Numbers are limited at 500 units per calendar year.
The SPCNS / SB100 Program is intended / meant for emission control for home built kit cars or hot rods. as of November 2009, California DMV has no pathway for a home builder to create a electric car without subscribing to the current SPCNS program, which was originally meant for historic replicas and gasoline powered cars.
Limitation: California SB100/SPCNS is limited to 500 cars per year. All 500 "sequence numbers" are consumed within minutes on the first DMV business day of the calendar year. SPCNS registration requires a significant paper trail on all frame/body/components, this is to assure stolen parts are not used in construction. Additionally, since registration fees and vehicle sales tax are generated from these figures, their requirement aids in revenue collection for each SPCNS number issued.
OFF-ROAD vehicles; "Kei car
Kei car
Kei cars, K-cars, or , are a Japanese category of small vehicles, including passenger cars, vans, and pickup trucks. They are designed to comply with Japanese government tax and insurance regulations, and in most rural areas are exempted from the requirement to certify that adequate parking is...
"-class trucks, four wheel sport "dirt" vehicles, and other utility vehicles imported and sold for off-road
Off-road vehicle
An off-road vehicle is considered to be any type of vehicle which is capable of driving on and off paved or gravel surface. It is generally characterized by having large tires with deep, open treads, a flexible suspension, or even caterpillar tracks...
use only; The electric conversion of a vehicle that was previously not certified for "On-Road" does not enable it to be registered for "On-Road" use with the conversion to electric power only. An example; certain subcompacts cannot qualify for registration except if a custom body or frame is installed to have the vehicle confirm to "On-Road" brake/light/safety standards.
As all originally ICE street-legal automobiles and light trucks built after 1975 must pass a smog test (including a "visual inspection"), a conversion of such a late model vehicle must be registered as an electric powered only vehicle and thus exempt. Otherwise, it would fail the required smog test, not for producing pollution, but for being altered from its original configuration and so failing the visual inspection portion of the test. Since 1975 and earlier vehicles are not currently tested for any smog compliance, it would be possible to convert them to electric power with little or no paperwork/certification issues.
It is no more simple if the vehicle is registered with current tags in California and may even be more difficult. Under new 2008 regulations for converted ICE vehicles a multi-step process is required. First, an appointment is made by telephone with a "Smog Referee". A meeting with the vehicle to be registered will typically be at a local community college with an extensive automotive shop program. The referee will inspect and certify that the vehicle is both smog exempt and that it qualifies for an "E" power code (electric-only). The next step requires real-time coordination between a cooperative clerk at the local California Department of Motor Vehicles (DMV) office and an appropriate clerk at the Sacramento
Sacramento, California
Sacramento is the capital city of the U.S. state of California and the county seat of Sacramento County. It is located at the confluence of the Sacramento River and the American River in the northern portion of California's expansive Central Valley. With a population of 466,488 at the 2010 census,...
office. (These procedures are in place to inhibit fraudulent registration of ICE vehicles as Electric in order to avoid smog inspections.) If the computer terminals are not operated in a coordinated manner the registration propulsion code will default to "Q" (hybrid vehicle
Hybrid vehicle
A hybrid vehicle is a vehicle that uses two or more distinct power sources to move the vehicle. The term most commonly refers to hybrid electric vehicles , which combine an internal combustion engine and one or more electric motors.-Power:...
) which is not exempt from smog inspection and the conversion will always fail such an inspection. Unfortunately, once the computer has defaulted to the "Q" code it is necessary to re-engage the Smog Referee to obtain a new prospective "E" code. The ability to successfully register as an electric vehicle is highly dependent upon the cooperation of the staff at the local office, their experience with registering electric vehicles, their ability to coordinate with Sacramento, and their interest in assisting you. Some offices will be much more accommodating than others. Multiple trips to the DMV office and the Referee are typically required.
Since no fuel or recharging taxes are collected the revenue that would otherwise be lost to the state is made up for with a substantial weight fee specific to electric vehicles registered for commercial use (no weight charges are added for noncommercial vehicles). While light ICE vehicles are taxed on a refined and progressive grading scheme, electric vehicles with commercial licenses are grouped into only a few broad categories, with the result that even a modest and lightweight commercially registered EV will pay the same tax as will a much heaver (up to 6000 lbs) EV. If an open-bed pickup truck (as opposed to a panel truck) is converted, the only way to register it as a non-commercial vehicle (and so avoid the weight fees) is to permanently install a camper shell
Camper shell
A camper shell is a small housing or rigid canopy used as a pickup truck accessory. The housing is usually made of fiberglass or aluminum, and is mounted atop the pickup truck's rear bed. It usually covers the entire bed of the pickup truck, and is large enough to be used for camping purposes...
(not a bed cover), which need not project above the truck cab nor include any other "camping" equipment. (This can be inconvenient if access to an in-bed battery box is required.) In California, one advantage of a commercial license is the ability to park in yellow zones, but only for short term pick-up and delivery.
Spain
In Spain, the conversion (called transformation) is regulated by the Royal Decree 736/1988, of 8 of July, por el que se regula la tramitación de las reformas de importancia de vehículos de carretera.See also
- Aftermarket (automotive)Aftermarket (automotive)The automotive aftermarket is the secondary market of the automotive industry, concerned with the manufacturing, remanufacturing, distribution, retailing, and installation of all vehicle parts, chemicals, tools, equipment and accessories for light and heavy vehicles, after the sale of the...
- Bright AutomotiveBright AutomotiveBright Automotive is a startup company based in Anderson, Indiana that is focused on creating a fuel-efficient line of plug-in electric vehicles. The company was started in 2008 with a team of employees from companies such as Google.org and Alcoa and has since designed its first vehicle, the IDEA...
- CalCarsCalCarsCalCars is a charitable, non-profit organization founded in 2002 to promote plug-in hybrid electric vehicles as a key to addressing oil dependence and global warming both nationally and internationally...
- Car tuningCar tuningCar tuning is both an industry and a hobby, in which an automobile is modified in order to improve its performance, handling and appearance. As most vehicles leave the factory set up for average driver expectations and average conditions, tuning has become a way to personalize the characteristics...
- CoachbuilderCoachbuilderA coachbuilder is a manufacturer of bodies for carriages or automobiles.The trade dates back several centuries. Rippon was active in the time of Queen Elizabeth I, Barker founded in 1710 by an officer in Queen Anne's Guards, Brewster a relative newcomer , formed in 1810. Others in Britain included...
- Electric carElectric carAn electric car is an automobile which is propelled by electric motor, using electrical energy stored in batteries or another energy storage device. Electric cars were popular in the late-19th century and early 20th century, until advances in internal combustion engine technology and mass...
- Engine swapEngine swapAn engine swap is the process of removing a car's engine and replacing it with another. This is done either because of failure, or to install a different engine, usually one that is more powerful or more modern and maintainable....
- Frame (vehicle)Frame (vehicle)A frame is the main structure of the chassis of a motor vehicle. All other components fasten to it; a term for this is design is body-on-frame construction.In 1920, every motor vehicle other than a few cars based on motorcycles had a frame...
- Gas-guzzlerGas-guzzlerGas-guzzler commonly refers to a vehicle that consumes fuel inefficiently.The term originally came into use in the US when congress established Gas Guzzler Tax provisions in the Energy Tax Act of 1978 to discourage the production and purchase of fuel-inefficient vehicles...
- Green tuning
- Helsinki Motor ShowHelsinki Motor ShowHelsinki Motor Show is an annual national car show in Helsinki, Finland. It is organized around November to December and it has been held in the Helsinki Fair Center. It is the only annual motor show in the Nordic countries....
- Manufacturer’s Certificate of OriginManufacturer’s Certificate of OriginA Manufacturer's Certificate of Origin , also known as a Manufacturer’s Statement of Origin , is a specified document certifying the country of origin of the merchandise required by certain foreign countries for tariff purposes, it sometimes requires the signature of the consulate of the country to...
(MCO) - Plug-in electric vehiclePlug-in electric vehicleA plug-in electric vehicle is any motor vehicle that can be recharged from any external source of electricity, such as wall sockets, and the electricity stored in the rechargeable battery packs drives or contributes to drive the wheels...
(PEV) - Plug-in hybrid (PHEV)
- PowertrainPowertrainIn a motor vehicle, the term powertrain or powerplant refers to the group of components that generate power and deliver it to the road surface, water, or air. This includes the engine, transmission, drive shafts, differentials, and the final drive...
- SEMASEMASpecialty Equipment Market Association of the automobile aftermarket was formed in 1963 by Roy Richter, Ed Iskenderian, Willie Garner, Bob Hedman, John Bartlett, Phil Weiand, Jr., Al Segal, Dean Moon, and Vic Edelbrock, Jr...
- Solar Golf CartSolar golf cartSolar golf carts are golf carts powered by mounting a photovoltaic or thin film panel on top of the existing roof or using a PV panel as the roof itself. A controller converts the sun's energy to charge the golf cart's 36-volt or 48-volt battery bank...
- Vehicle gliderVehicle gliderIn automobiles, a glider is a vehicle without a powertrain . It is generally a brand new car, but a second-hand car can also be used...
- Venture capitalVenture capitalVenture capital is financial capital provided to early-stage, high-potential, high risk, growth startup companies. The venture capital fund makes money by owning equity in the companies it invests in, which usually have a novel technology or business model in high technology industries, such as...
External links
- eCars - Now!, an open sourceOpen sourceThe term open source describes practices in production and development that promote access to the end product's source materials. Some consider open source a philosophy, others consider it a pragmatic methodology...
community devoted to develop high quality electric car conversions available for everyone. - CalCars ICE Conversions- Campaign to Electrify World's 900+ Million Vehicles
- EAS Electric Autosports Inc. Automobile and marine conversions and components sales In Vancouver, Canada
- Pacific Electric Vehicle Conversions in Seattle, WA
- Electric Vehicle Conversion Kit Manufacturers in the World
- Conversions to Electrify World's 900+ Million Cars (CalCarsCalCarsCalCars is a charitable, non-profit organization founded in 2002 to promote plug-in hybrid electric vehicles as a key to addressing oil dependence and global warming both nationally and internationally...
). - REEV DIY Association
- Business up for electric car conversions.
- Wilderness EV, car conversions.
- Top 7 Issues for an EV Conversion
- The EV Photo Album - Contains photos and information of many types/styles of EVs and EV Conversions
- The Electric Vehicle Discussion List (EVDL)
- Books, manuals, and guides about converting cars to electric
- How to build an electric car
- An ectricelectric motorcycle builder shows construction details
- Grassroots Electric Vehicles
- A step-by-step Battery Electric Vehicle conversion (with video)
- Green Motors conversions.
- Nationwide Reservations for Electric Vehicle Conversions
- Colin McCubbin's Pontiac firefly convertible Ev conversion site.
- Vancouver Electric Vehicle Association's site.
- Yearly Conversion Workshops by Bucks County Renewables
- EVE conversion kits