Embarking on an electric vehicle (EV) conversion is an exciting journey for any car enthusiast or environmentally conscious individual. The idea of transforming a traditional combustion engine vehicle into a modern, emission-free EV is compelling. For those looking to undertake this challenge, understanding where to source Electric Car Conversion Parts is the first crucial step. This article will explore the world of DIY EV conversions, focusing on sourcing components and key considerations for your project, drawing insights from real-world experiences in the field.
Close up view of the high voltage connections on a Mitsubishi Outlander front inverter motor/generator, highlighting the complexity of OEM EV components.
The Rise of DIY Electric Vehicle Conversions
The concept of converting gasoline cars to electric isn’t new, with roots stretching back decades. However, the modern resurgence is fueled by the increasing availability of electric car technology and a growing community of enthusiasts sharing knowledge and resources. The significant shift occurred as factory-produced EVs became more commonplace, ironically paving the way for DIY conversions. This is because the market now offers a supply of used and salvaged EV components, making projects more accessible and potentially more affordable than ever before.
For many, like myself, the allure of DIY EV conversion stems from several key factors:
1. The Joy of Building and Understanding: There’s immense satisfaction in constructing something yourself, gaining deep knowledge of its inner workings, and possessing the ability to maintain and modify it. This hands-on approach offers a level of engagement that simply buying a ready-made EV cannot replicate.
2. Repurposing and Value in Salvage EVs: Salvage electric vehicles often represent an untapped resource. Many perfectly functional EV components end up scrapped simply due to minor accidents or changing market demands. Repurposing these electric car conversion parts is not only cost-effective but also environmentally responsible, giving a second life to valuable engineering and reducing waste. This is especially relevant in regions where right-to-repair initiatives are gaining traction, encouraging the reuse of automotive components.
3. A Preference for Simpler Vehicles: Modern cars, while technologically advanced, can feel overly complex and somewhat generic. Many drivers appreciate the character and simplicity of older vehicles. Converting a classic or slightly older car allows for the integration of modern EV technology while retaining the charm and driving experience of a vehicle they genuinely enjoy.
4. Skepticism Towards Over-reliance on Automotive Computers: The sheer number of computer systems in modern vehicles raises questions about their necessity and long-term reliability. For those with a background in technology, a simpler, more transparent system can be more appealing and maintainable. DIY EV conversions offer a chance to build a sophisticated vehicle without the opaque complexity of proprietary automotive software.
Defining Goals for Your EV Conversion Project
Before diving into sourcing electric car conversion parts, it’s essential to define clear goals for your project. These goals will guide your choices in components, budget, and the overall approach. Key considerations include:
1. Learning and Contribution: For many DIY converters, the project is as much about the journey as the destination. Contributing to the open-source EV community and expanding personal knowledge of EV technology are often primary motivators.
2. Practical Daily Driver: The converted EV should ideally serve as a functional and reliable vehicle for everyday use. This means considering factors like comfort, safety features (such as airbags and ABS), and practicality for daily tasks.
3. Range and Performance Requirements: Determine the necessary range for your typical driving needs. Consider daily commutes, longer trips, and the availability of charging infrastructure in your area. Performance expectations, such as acceleration and top speed, will also influence motor and battery choices. A realistic range target is crucial for selecting appropriate electric car conversion parts, especially batteries.
4. Budget Constraints: EV conversions can range significantly in cost. Setting a realistic budget early on will help guide decisions about component selection, project scope, and acceptable compromises. It’s important to balance desired performance and range with financial limitations.
Initially, the idea of an electric utility vehicle (ute) might seem appealing due to their practicality. However, the increased weight and aerodynamic challenges of utes often require larger, more expensive battery packs and motors to achieve a satisfactory range, potentially exceeding a reasonable budget.
Sourcing Salvage EV Parts: The Outlander PHEV Example
One effective approach to sourcing electric car conversion parts is through salvage vehicles. Plugin hybrid electric vehicles (PHEVs) like the Mitsubishi Outlander PHEV are particularly interesting because they contain a wealth of EV components alongside traditional combustion engine parts.
A salvaged Mitsubishi Outlander PHEV acquired for parts, demonstrating a cost-effective source for EV conversion components.
PHEVs are complex machines, incorporating:
- Complete EV Powertrain: Including electric motors, inverters, and charging systems.
- Combustion Engine Components: Engine, fuel tank, exhaust, and related systems.
- Hybrid Transmission Systems: Complex transmissions designed to integrate both electric and combustion power sources.
- High Voltage Battery Pack: While smaller than in a full EV, PHEVs still contain a usable high-voltage battery.
The complexity of PHEVs, paradoxically, can make them a cost-effective source of electric car conversion parts. Due to the smaller battery packs and market dynamics, PHEVs can sometimes be acquired at a lower overall cost than comparable battery electric vehicles (BEVs), despite containing a significant amount of valuable EV technology.
Salvage auctions are a prime location to find such vehicles. Cars written off due to accidents, even with relatively minor damage, can be acquired for a fraction of their original price. For example, a crashed Mitsubishi Outlander PHEV, despite being relatively new, might be available at salvage auctions for significantly less than its market value, offering a rich source of components for EV conversion projects.
The engine bay of an Outlander PHEV, illustrating the dense packaging of both combustion engine and electric vehicle components.
The Outlander PHEV, in particular, is attractive due to its multiple electric motors. It features two motors in the front transaxle and a separate motor driving the rear axle, providing all-wheel drive capability through electric means, without a traditional mechanical driveshaft.
Close view of the damaged engine bay of a salvaged Outlander, showing the type of damage that can lead to a vehicle being written off despite potentially functional EV components.
The open-source community, particularly groups like openinverter, has made significant progress in understanding and controlling OEM EV components like those found in the Outlander. They have documented CAN bus communication protocols and control strategies, making it feasible to repurpose these parts in DIY conversions. This community knowledge is invaluable when working with salvaged electric car conversion parts.
Analyzing Outlander EV Components: Motors and Performance
The Mitsubishi Outlander PHEV offers a good example of readily available electric car conversion parts. It boasts multiple electric motors:
Front transaxle of a Mitsubishi Outlander, revealing the integrated electric motors and transmission unit.
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Front Motor/Generator: Technically one unit functions as a motor and the other as a generator driven by the combustion engine. However, both are essentially three-phase AC electric motors. These can be independently controlled for EV conversion purposes.
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Rear Motor: Integrated with a fixed gear reduction, the rear motor provides direct drive to the rear wheels, enabling electric all-wheel drive.
The performance specifications of these motors are suitable for many conversion projects. The front motor is rated at 60kW power and 135Nm torque, while the rear motor offers 60kW and 195Nm. While not “ludicrous” in performance terms, this power level is adequate for a comfortable and practical daily driver.
It’s worth noting that the stock power output might be limited by the original battery pack’s capabilities. The Outlander’s 12.8kWh battery pack is relatively small, and pushing the motors to higher power levels might require a battery with a higher C-rating (discharge rate). However, for many conversions, the stock power levels offer a good balance of performance and efficiency.
Vehicle Communication and Diagnostics: CAN Bus Logging
Working with modern electric car conversion parts often involves understanding and utilizing Controller Area Network (CAN bus) communication. OEM EV components rely heavily on CAN bus for control signals and data exchange.
Setting up CAN bus logging inside a salvaged Outlander to understand vehicle communication protocols, essential for repurposing OEM EV parts.
Logging and analyzing CAN bus data is crucial for:
- Understanding Component Communication: Deciphering the CAN messages allows you to understand how different EV components communicate and how to send control signals.
- Troubleshooting and Diagnostics: CAN bus data can reveal fault codes and system status, aiding in troubleshooting issues during the conversion process.
- Reverse Engineering and Control: By analyzing CAN data, it’s possible to reverse engineer the control protocols and develop custom controllers for repurposed EV parts.
Tools like CAN bus analyzers and software are essential for this process. Capturing and studying CAN logs from salvage vehicles provides invaluable insights into the operation of OEM EV systems and how to integrate electric car conversion parts effectively.
Dashboard of the salvaged Outlander displaying fault codes, highlighting the need for diagnostic skills when working with modern vehicle electronics.
Furthermore, dealing with salvage vehicles often involves clearing fault codes and understanding vehicle diagnostic systems. Modern cars are designed to enter safe modes or disable certain functions after accidents. Knowing how to reset systems and bypass immobilizers is often necessary to even begin working with salvaged electric car conversion parts.
Using an oscilloscope and CAN logger to analyze the Battery Management System (BMS) of the Outlander, a critical step in understanding and reusing salvaged EV batteries.
Battery Considerations: The Heart of EV Conversion
Batteries are arguably the most critical and challenging component in any EV conversion. They represent a significant portion of the cost, weight, and complexity. Key factors to consider include:
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Weight Limits: Vehicle regulations impose strict Gross Vehicle Mass (GVM) limits. Adding a battery pack can significantly increase vehicle weight. Careful calculation and planning are needed to ensure the converted vehicle remains within legal limits and maintains safe handling characteristics.
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Power and C-Rating: Battery C-rating dictates the rate at which a battery can discharge power. Matching battery C-rating to motor power requirements is crucial for achieving desired performance. Insufficient C-rating can limit acceleration and overall power output.
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Cost: EV batteries are a major expense. Balancing desired range and performance with budget constraints is a key challenge. Exploring different battery chemistries and sourcing options is essential.
New lithium iron phosphate (LFP) cells from manufacturers like EVE offer a promising balance of cost, performance, and safety. LFP batteries are known for their longer lifespan and thermal stability, making them a popular choice for DIY EV conversions. A 30kWh LFP battery pack can provide a reasonable range for many applications while remaining within a manageable budget and weight.
(Photo courtesy EVE Energy Co. alibaba store)
Vehicle Selection: Finding the Right Conversion Candidate
Choosing the right vehicle for conversion is crucial for project success. Considerations include:
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Vehicle Weight and GVM: Vehicles with a higher GVM and lower original weight offer more flexibility for adding battery packs without exceeding weight limits.
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Safety Features: Modern safety features like airbags and ABS are desirable for a daily driver EV conversion. This generally points towards vehicles from the late 1990s onwards.
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Vehicle Condition and Simplicity: While older classic cars can be appealing for conversions, they often lack modern safety features and may present challenges in integrating with newer EV components. A balance between simplicity and modern features is often ideal.
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Availability and Cost: Used car prices and availability can fluctuate. Market conditions and vehicle popularity influence the overall cost of the conversion project.
Vehicles like the Peugeot 406, with their comfortable ride, reasonable weight allowance, and availability at reasonable prices, can be excellent candidates for EV conversions. Their original diesel powertrains, while fuel-efficient, can be replaced with cleaner and more efficient electric systems, resulting in a vehicle that is both enjoyable to drive and environmentally friendly.
An Alfa 147, a less successful vehicle choice highlighting the importance of careful vehicle selection for EV conversion projects.
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A Peugeot 406, a more practical and comfortable vehicle choice, offering a good platform for a DIY electric car conversion.
The Peugeot 406, registered and ready for its transformation into an electric vehicle, showcasing a suitable candidate for DIY conversion.
Avoiding the “Substandard Leaf Trap”
A key consideration throughout the EV conversion process is to ensure the final product is genuinely worthwhile. It’s important to avoid creating a “substandard Nissan Leaf” – a converted EV that underperforms or offers a worse driving experience than a commercially available used EV like a Nissan Leaf.
The goal is to build something unique and enjoyable, leveraging the advantages of DIY conversion while achieving a functional and satisfying electric vehicle. Careful planning, component selection, and execution are essential to ensure the converted EV is not only a testament to DIY ingenuity but also a practical and enjoyable vehicle to drive.
The journey of EV conversion is full of learning and discovery. By carefully sourcing electric car conversion parts, defining clear goals, and leveraging community knowledge, enthusiasts can successfully transform gasoline vehicles into modern, emission-free EVs, contributing to a more sustainable and exciting automotive future.
