The automotive world is rapidly evolving, driven by the urgent need for fuel efficiency, stricter environmental regulations, and a global push for ecological sustainability. Electric vehicles (EVs) are at the forefront of this change, capturing the attention of drivers worldwide who are increasingly conscious of their environmental impact.
Beyond the clear environmental advantages, electric cars offer compelling economic benefits. The lower running costs, primarily due to electricity being significantly cheaper than gasoline or diesel, are a major draw. This combination of ecological and economic appeal is fueling the growth of both the new EV market and the burgeoning sector of Part Electric Cars, specifically the electric car conversion market.
The concept of upcycling classic cars by converting them to electric power is no longer a futuristic dream but an economically viable and increasingly accessible option. The technology and expertise required for these transformations have advanced significantly in recent years.
Many people are unaware that they can transform their existing gasoline or diesel vehicles into part electric cars by replacing the internal combustion engine and transmission with an electric powertrain. While brand-new electric models can be financially out of reach for many, and the used EV market is still developing, converting an older car presents a practical and exciting alternative. Drivers are increasingly choosing to convert older cars, substituting traditional engines with modern batteries and electric motors.
If you’re contemplating joining this electric revolution and converting your car, there are essential aspects to understand. Electric vehicles operate on fundamentally different principles than their fossil fuel counterparts. This article will delve into the core components and operational mechanisms of an electric car conversion, illuminating how these fascinating transformations are achieved.
How Does a Part Electric Car Conversion Actually Work?
Unlike traditional vehicles powered by internal combustion engines, part electric cars – specifically conversions – are propelled by an electric motor. This motor draws its power from a high-voltage battery pack. The amount of electricity supplied to the motor is directly controlled by the accelerator pedal, giving the driver precise control over speed and power.
Here’s a breakdown of what happens when you press the accelerator in a converted electric car:
- Motor Controller (Inverter) Activation: Acting as the central processing unit, the motor controller, also known as the inverter, receives the signal from the accelerator pedal. It instantly calculates the precise power demand from the battery pack.
- Power Delivery: Based on the accelerator input, the inverter directs the required amount of electrical energy from the battery pack to the electric motor. The harder you press the pedal, the more power is released.
- Energy Conversion: Within the electric motor, electrical energy undergoes a remarkable transformation into mechanical (rotational) energy. This conversion is achieved through the interaction of electromagnets and wire coils within the motor.
- Transmission Engagement: The motor’s output shaft begins to rotate, engaging with the transmission.
- Wheel Propulsion: The transmission plays a crucial role in adjusting the motor’s rotational speed into a usable speed for the drivetrain components – axles, differentials, driveshafts, etc. This coordinated action ultimately turns the wheels, propelling the part electric car forward.
Key Components of a Part Electric Car Conversion
Battery Pack: The Heart of the Conversion
The battery pack stands as the most crucial and substantial component in any part electric car conversion. It is not only the largest and heaviest part but also the most expensive, fundamentally dictating the vehicle’s power and driving range. A battery pack is an assembly of interconnected individual batteries, typically ranging from 5 to 25 modules. Each module contains hundreds of individual cells, often sourced from production electric vehicles to ensure quality and performance.
The battery pack is securely housed within a custom-engineered metal battery box. This box is designed to fit seamlessly into the original engine bay of the vehicle being converted, maximizing space utilization. For conversions demanding extended range, a secondary battery box can be incorporated, often placed in the trunk or beneath the rear seats, to accommodate additional batteries.
Encased within this protective battery box are critical electronic components that manage and monitor the entire pack. An ignition system controls the power flow, enabling the car to be switched on and off safely.
A vital element within the battery box is the Battery Management System (BMS). This sophisticated system continuously monitors crucial parameters such as voltage, temperature, and current flow during both charging and discharging cycles. The BMS is essential for preventing battery damage from overheating or voltage irregularities, ensuring optimal battery health and longevity.
The BMS is in constant communication with the charging system and motor controller, exchanging signals to guarantee the battery pack operates at peak efficiency and safety.
Furthermore, the battery box incorporates a sophisticated cooling system. This system, featuring an external radiator and water pump, circulates coolant throughout the battery pack. This thermal management is crucial for maintaining consistent temperatures across all batteries, preventing overheating, and ensuring optimal motor performance.
Power Inverter/Controller: The Energy Translator
The inverter, also known as the motor controller, acts as the vital intermediary between the battery pack and the electric motor in a part electric car. Its primary function is to convert direct current (DC) from the batteries into alternating current (AC). Electric motors typically require AC power to operate efficiently. Think of the inverter as the translator in the system; without it, the motor would receive unregulated DC power, leading to uncontrolled spinning at full speed.
The motor controller is intricately linked to both the vehicle’s throttle and the Battery Management System. This connection allows it to precisely regulate the power delivered to the motor based on driver input and battery status.
Inverters handle substantial electrical currents, especially during periods of high power demand, such as rapid acceleration. To manage heat generated during this process, inverters are integrated into the battery cooling system. Coolant circulation ensures the inverter operates within its optimal temperature range, preventing performance degradation or damage.
A remarkable feature of modern inverters is their ability to facilitate regenerative braking. During braking, the inverter can reverse the energy flow, converting the motor’s kinetic energy back into electrical energy. This recovered energy is then used to recharge the battery, enhancing the efficiency and range of the part electric car.
Electric Motor: The Propulsion Powerhouse
The electric motor is the workhorse of a part electric car, responsible for converting electrical energy into the mechanical energy that ultimately propels the vehicle. Motors come in various types, with some operating on direct current (DC) and others on alternating current (AC). For electric vehicle conversions, AC motors are generally favored due to their superior efficiency and performance characteristics. An electric motor essentially functions as a large, precisely engineered electromagnet that rotates due to the principles of magnetic attraction and repulsion.
A significant advantage of electric motors is their exceptional energy efficiency. They convert over 85% of electrical energy into mechanical energy, a stark contrast to the less than 40% efficiency of a typical gasoline combustion engine. (Source: NRDC.org)
Electric motors are available in a wide range of sizes and power outputs. For a standard classic car conversion, a motor producing around 120 horsepower might be suitable. In contrast, high-performance motors, like those found in Tesla vehicles, can generate upwards of 500 horsepower, offering exhilarating performance when desired.
The motor’s rotational output is directed to the transmission (gearbox). Conversions can utilize either the original gearbox of the vehicle or a single-speed unit specifically designed for electric powertrains. Retaining the original gearbox can be a cost-effective approach for classic car conversions, minimizing the need for extensive fabrication of new drivetrain components. In this scenario, only adapter plates are typically required to mate the electric motor to the existing transmission.
However, using high-performance motors like Tesla drive units often necessitates a more complex and costly approach. These units are typically axle-mounted, requiring custom half-shafts, differentials, and drivetrains to be engineered and installed, substantially increasing the overall conversion expense.
Ancillary Components in a Part Electric Car
Charger: Refueling with Electricity
An essential component of a part electric car is the onboard charger. This device performs the crucial task of converting AC power from the electrical grid into DC power, which is then used to replenish the high-voltage batteries.
Electric vehicle chargers are designed with intelligent features to ensure safe and efficient charging at appropriate speeds. The charger is integrated within the car, allowing for convenient charging at various locations, including homes, parking lots, and public charging stations.
Chargers are available in different power ratings, significantly impacting charging speeds. However, even the most powerful charger is limited by the power supply available. A standard household outlet in the UK, for example, typically provides a maximum charging rate of 2-3 kWh. In contrast, wall-mounted charging systems, commonly installed at homes or found at service stations, can deliver 10 kWh or more, dramatically reducing charging times.
Electric Car Converts recommends installing a dedicated electric car charger at home for convenient and faster charging. Their partners at Go Electrik specialize in home charger installations and can provide expert assistance.
DC/DC Converter: Powering Ancillary Systems
The DC/DC converter is a vital component that ensures compatibility with the vehicle’s existing electrical systems in a part electric car conversion. It efficiently transforms the high-voltage DC power from the main battery pack down to the standard 12V DC required to operate the car’s original 12V systems.
These 12V systems are essential for powering various functions, including lights, windshield wipers, and central locking. The DC/DC converter eliminates the need for extensive rewiring of these systems during the conversion process, significantly reducing complexity and cost.
Thermal Management System (Cooling): Maintaining Optimal Temperatures
While electric vehicles boast impressive efficiency, with over 85% of electrical energy converted to motion, some heat generation is inevitable. Although typically not extreme, managing this heat is crucial for protecting sensitive components and ensuring optimal performance in a part electric car.
While some components benefit from air cooling, critical components like batteries and the motor controller (inverter) necessitate dedicated cooling systems. The thermal management system in an EV typically comprises a compact radiator, a fan, a coolant pump, and associated plumbing to circulate coolant fluid. This closed-loop system effectively dissipates heat away from heat-sensitive components, maintaining stable operating temperatures.
The electric car cooling system is built around three main elements:
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Radiator: This component is responsible for cooling the circulating coolant fluid, dissipating heat into the surrounding air.
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Coolant: A specialized fluid formulated to efficiently absorb and transfer heat away from the electric car’s components.
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Fan: The fan enhances airflow across the radiator, particularly crucial in slow-moving traffic where natural airflow is minimal, ensuring effective cooling.
Charging Port: Connecting to the Grid
The charging port serves as the interface for connecting the part electric car to external power sources for recharging. It is usually strategically located where the original fuel filler was positioned, maintaining a familiar access point. The charging port directly links to the onboard charging system, facilitating the transfer of electricity to the high-voltage battery pack.
In the UK and Europe, electric vehicle conversions commonly utilize Type 2 charging plugs. This standardization ensures compatibility with the widespread charging infrastructure, allowing drivers to charge their vehicles at various locations without needing adapters or specialized cables.
Many owners of part electric cars are surprised to learn that they can also charge their vehicles using a standard 3-pin household socket in the UK. While slower, this option provides flexibility and eliminates range anxiety, ensuring charging is possible even without access to dedicated charging stations. Electric Car Converts’ battery packs, for instance, can achieve a full charge from 0-100% in approximately 8 hours using a standard plug, and this time is halved to around 4 hours with a dedicated wall-mounted charging station.
Electric Car Converts: Leading the Charge in Conversions
Electric vehicles represent the future of personal transportation. For EVs to fully displace gasoline-powered cars, a fundamental shift in both mindset and technology is essential. Part electric cars, through conversions, offer a tangible and exciting pathway to accelerate this transition.
As technology continues to advance, electric cars, including conversions, are poised to become increasingly affordable and accessible to a wider audience. While the inner workings of electric cars involve a range of components that may be unfamiliar to many drivers, understanding these elements demystifies the technology and highlights the ingenuity behind part electric cars. We trust this guide has provided valuable insights into the fascinating world of electric car conversions.
Electric Car Converts stands at the forefront of EV conversion expertise. If you have any questions about transforming your car into a part electric car, their team is ready to provide expert guidance and support.
Reviewed by Barnaby Birkbeck (Founder) & Toby Wilson (Head Electrical Engineer), in 2025.
This article has been reviewed by our team of professional experts for accuracy and relevance. However, the information provided is for general informational purposes only. We recommend consulting with us for personalised guidance.
