Designing an electric vehicle conversion

National efforts to improve air quality in heavily populated urban communities-by reducing vehicular tailpipe emissions-have rekindled interest in the development of electric vehicle technology and infrastructure. Electric vehicles make ideal urban-commuter vehicles, for driving to and from, and within a city. However, electric vehicles are currently manufactured only in low volumes, and consequently the price of most commercially available electric vehicles remains high. It is possible, however, to build, an electric vehicle by “converting” a gasoline-powered vehicle, that is, replacing the internal combustion engine in an existing gasoline powered vehicle with an electric drive-train. This process is called “electric vehicle conversion”, and has become popular among hobbyists, schools, and clean-air enthusiasts, as a means of providing an immediate solution to clean-air transportation. Many of the commercial electric vehicles sold in the USA are electric vehicle conversions. This paper addresses the design considerations involved in the conversion of a gasoline-powered vehicle to electric. Discussion of the various design elements in an electric vehicle conversion include: removal of internal combustion engine and related parts, choice of electric vehicle components, installation of electric vehicle components, and integration of electric vehicle accessory systems. For practical purposes, this paper limits consideration of EV components available at a cost that reflects high-volume production