- 1). Double check to make sure that all of your logistical needs are met. Make sure that you have the facilities to build your converted vehicle, where you car will be protected from the elements for at least a couple of months to a year, depending on your availability to dedicate time to work on the car. Also make sure that you have the budget for at least $5,000 for parts including the conversion kit, tools and batteries. Check to make sure that you have easy access to charging your vehicle when the conversion is complete.
- 2). Take out the bolts that connect the engine to your vehicle. Also remove all of the radiator system, gas tank, fuel lines, exhaust system and emission wires and hoses. Recycle as much of the actual metal as possible, or sell it to a junkyard which might be able to salvage the parts. Be sure to keep hold of the transmission, clutch and the flywheel, as you will need these parts and systems for your electric conversion. Be sure that you also label where each wire goes before removing the engine. Particularly, label the ignition wires and accelerator cable.
- 3). Degrease and paint the engine compartment. You will want a clean space for your electric conversion kit.
- 4). Reinstall an electric motor, which will be mounted to the transmission with an aluminum adapter plate and spacer ring. Attach the hub of the motor shaft to the flywheel with the set screws that attach the two pieces together. Bolt the spacer plate and adapter plate into place and bolt the flywheel to the electric motor hub. Next, bolt the clutch to the flywheel, and make sure that all bolts are tightened correctly with the torque wrench.
- 5). Lower the motor to the engine bay and bolt it to the transmission. Put the car in gear and rotate the tires so that the motor shaft also rotates. If it does not rotate, then it has not been properly aligned with the transmission. Check all of the gears by hooking the motor up to a 12-volt battery and running the engine, making sure everything is balanced and working properly.
- 6). Install the heater pump. This will differ depending on which type of conversion kit you have bought.
- 7). Secure the motor end that is not attached to the transmission, bolting it to the frame of the car. Weld braces and mounts so that the engine is securely in place. Place the components of the electric vehicle system securely next to the motor so that the contactor, controller, DC-DC converter and pot box are all close together and wired according to the directions of your kit.
- 8). Mount PVC pipe beneath the car, which will serve as a conduit for wiring to run to the rear battery. Install a battery box, by mounting it with bolts, in the trunk to ensure that fumes do not leak into the passenger compartments of the car. Place the deep cycle batteries in the battery box. Wire the car according to the instructions from the conversion kit.
previous post