Vehicle Conversion
Love the look of your old classic car but want to move into the modern era of EV technology? We’ve got great custom solutions for just about any vehicle.
EV Conversion Experts
Our EV conversion offerings are unmatched in the industry. While we particularly enjoy converting classic cars to EV’s, we can transform almost any vehicle into its EV counterpart.
Here’s some insight into the EV conversion process:
The Process
01
Project Planning
Before the first bolt is removed, we’ll determine what we need to accomplish in terms of vehicle range, working conditions, and performance. We’ll select a battery chemistry and form factor that works best with the target vehicle. We’ll decide on the operating voltage, and accordingly–the best battery configuration.
02
Engine Extraction
During this phase, we’ll remove the combustion-oriented components, like the engine, exhaust, fuel tank, and portions of the cooling system. We’ll clean up the engine bay and assess the initial layout for the engine in relation to other components.
03
LASER Scanning and CAD Analysis
This stage involves LASER-scanning the volumetric spaces within the vehicle’s frame and other cavities. This important step allows us to determine exactly how much available space we’re working with, and the exact form factor of the various bracketry that we’ll need to fabricate. We’ll note the components that relied on the combustion engine (like HVAC) so they can be substituted with EV-compatible counterparts.
04
Chassis Preparation
Before rebuilding, we’ll freshen up the chassis and address any issues like damage, wear-and-tear, and surface rust. We replace bearings, shocks, brakes, tires, and other wearable parts. We’ll finish by applying a resilient layer of rubberized undercoating to the entire frame.
05
Body Preparation
Similarly to the prior step, we’ll prepare the body for reinstallation, including addressing cosmetic issues, rust, fitment, and other abnormalities. We’ll also verify physically, that newly-created components will fit seamlessly into the legacy body.
06
Preparation of Electrical Components
We’ll prepare the looms of wiring harnesses necessary to make the new motor perform. Electrical components will be prepared in accordance with industry best practices in order to prevent premature degradation due to exposure to the elements.
07
Battery Fabrication
This labor-intensive stage involves assembling the battery into multiple packs that will be distributed evenly throughout the vehicle. We’ll try to keep weight distribution as consistent as possible, and similar to the original vehicle. We’ll fabricate the battery boxes and ensure they are reliably mounted to the vehicle’s frame.
08
Road Tests
When everything is assembled, it’s time to take the vehicle on the road. We’ll observe the vehicle’s behaviors in a variety of conditions that vary in terms of temperature, precipitation, terrain, and load. We’ll check for unusual sounds, vibrations or other abnormalities that might indicate that an adjustment is needed. We’ll assess the overall driving experience for safety and comfort. Lastly, we’ll monitor battery temperatures and range to ensure the system is operating within our design specification.
09
Software Tuning
EV motor controllers are highly configurable, allowing us to tune the system for the specific performance characteristics we need. We can regulate the maximum speed or acceleration characteristics in order to avoid undue strain on the mechanical components. We can adjust the regenerative braking to provide the optimum balance between range and driving convenience.
