Converting to Electric Without Losing Comfort

Keeping Creature Comforts, Even When Gas is Gone!

Electric motors do not need to be running when the vehicle is stopped, and they generate significantly less heat than their internal-combustion-engine (ICE) counterparts. Most vehicles using ICEs rely on a serpentine or accessory belt to convert this idle energy to charge a 12V battery via an alternator, spin an A/C compressor, and run a power-steering pump. Furthermore, hot engine coolant is used to heat the cab via a heater core, and the negative pressure at the intake may be used to assist power braking or control other auxiliary functions. 

When we convert a vehicle to an electric powertrain, we lose all these passive functions of the engine. How do we retain these creature comforts in a converted vehicle? Read on to find out!

12V Accessories

Rather than use an alternator to charge a 12V battery, we now use a component called a DC-DC converter to power the 12V system. The DC-DC converter steps down the high-voltage DC power stored in the battery pack (at 100V , 400V, or even 800V!) to low-voltage DC power to keep our 12V battery topped off. Then, all existing 12V components such as lights, wipers, stereos, and power windows, stay in the vehicle operating in the same way as they did before. Not only does this simplify the conversion process, it also keeps voltage in the EV accessory systems as low as possible, which results in a safer build.

DC-DC converters are available  as stand-alone components or come packaged in a combined charge unit, which also includes on-board charger functions. DC-DC converters can be sourced in 1kW to 2.7kW power outputs, which can provide 73A to 197A of DC current to a 12V battery.

Heater

In an ICE-operated car, hot engine coolant is blown over the heater core, and that heated air is then distributed throughout the cab. In an EV, we replace hot engine coolant with HV DC power as the source of heat. In some cases, a ceramic electric heater replaces the heater core completely. In other cases, the existing heater core is reused by adding a small liquid heater to the heater core circuit. We use the HV DC power available in the batteries to keep current low and associated electrical conductors small for the same power output.

all existing 12V components such as lights, wipers, stereos, and power windows, stay in the vehicle operating in the same way as they did before.

A/C

Very similarly to the heating system in an EV, the A/C compressor works much the same. The belt-driven A/C compressor is replaced with a HV A/C compressor to compress the refrigerant in your typical automotive A/C system. We can switch the A/C compressor off and on by using the compressor clutch signal that the belt-driven A/C compressor used or by using a CAN bus signal. Again, we use the HV battery as the power source to keep current low while providing plenty of power to cool the cab of the vehicle.

Power Steering

There are two primary ways to retain power steering in a converted vehicle. First, you can use an external electric power steering pump and then keep the existing rack-and-pinion. Alternatively, an electric power steering (EPS) can be used. EPS uses an electric motor to provide turn assistance to the steering system. The motor is activated by electronic sensors that detect the amount of steering lock being applied by the driver. This is used in both ICE and electric vehicles.

By implementing a few key component swaps, we are able to keep all the creature comforts that we are familiar with when switching from gas to electric powertrains. 

Power Brakes

There are three primary ways in an EV to retain power braking depending on the existing system present in the vehicle. First, a 12V vacuum pump can be added to the system to provide a source of negative pressure for vacuum boosted brakes. Secondly, hydroboost brakes can be utilized with the addition of a fluid pump. Lastly, we can add an electronic brake booster to add more stopping power.

Another thing to consider when talking about brakes in an EV is that most can use regenerative braking to slow down the vehicle. This means that under normal operation, less brake pressure is needed to slow down the vehicle. The added benefit of regenerative braking is that the kinetic energy of the moving vehicle can be converted back into electric energy to charge the battery and extend the range of the vehicle.

By implementing a few key component swaps, we are able to keep all the creature comforts that we are familiar with when switching from gas to electric powertrains. In many cases, the new accessories require less maintenance creating an even more enjoyable ownership experience.

FREQUENTLY ASKED QUESTIONS

What are EV conversion kits, and how do they differ?

EV conversion kits are essentially packages that allow you to transform a traditional gasoline-powered vehicle into an electric one. These kits provide the necessary components to replace the internal combustion engine with an electric motor and battery setup, promoting sustainability and reducing carbon emissions.

Types of EV Conversion Kits

There are two primary types of conversion kits: custom kits and universal kits.

1. Custom Kits:
   • Tailored specifically for certain vehicle models.
   • Include comprehensive components like the drive system and custom-made battery racks.
   • Offer a seamless integration for your particular car, ensuring all parts fit perfectly.
2. Universal Kits:
   • Designed to fit a variety of vehicles, offering flexibility in choice.
   • Contain vital components like the electric motor and controllers.
   • Require the buyer to create or source additional custom parts, such as battery mounts or enclosures, to fit their specific vehicle.

Choosing the Right Kit

• Consider Compatibility: If you have a popular vehicle model, custom kits may provide an easier and more straightforward installation process.
• Think Flexibility: Universal kits are ideal if you wish to apply the conversion to different vehicles or if your vehicle is less common.

By understanding the differences between these kits, you can choose the best solution tailored to your needs and vehicle type.

How much do electric vehicle conversion kits cost?

When considering electric vehicle (EV) conversion kits, the investment varies significantly based on the components and compatibility with your car. Here’s a closer look at the cost breakdown:

• Basic Conversion Kit: You can expect a starting price of around $8,000. This cost covers essential components required to switch from a conventional to an electric drivetrain.
• Battery Packs: The battery is a critical part of the conversion and can add another $1,000 to $3,000 to the total cost. The exact price depends on the battery capacity and brand you choose.

While the initial outlay might seem substantial, converting an existing vehicle to electric is generally more affordable than purchasing a new EV or paying a professional conversion company, which might charge a sum comparable to buying a new car.

In summary, the total expenses for converting your vehicle could start from $9,000 upwards, depending on your specific needs and preferences.

What is the cost of converting a gas-powered car to an electric vehicle?

How Much Does It Cost to Convert a Gas-Powered Car to an Electric Vehicle?

Converting a traditional gas-powered vehicle into an electric one involves several costs. First, you’ll want to consider the primary components: parts and labor.

1. Parts: The essential parts for this transformation generally cost around $6,000. This includes the electric motor, controller, and other necessary modifications to accommodate electric drive.
2. Batteries and Installation: Batteries are a significant part of the conversion. Expect to spend between $1,000 and $3,000 for both the batteries themselves and the installation process.

For those looking to enhance performance or upgrade with premium components, costs can rise substantially. In more upscale conversions, you could spend upwards of $20,000 or more.

Benefits of an Electric Conversion

While the initial investment might seem steep, the advantages make it worthwhile. An electric vehicle (EV) generally incurs much lower running costs—just a few cents per mile. Additionally, EVs offer increased reliability and require far less maintenance than their traditional gas-powered counterparts, potentially saving further costs over time.

Which cars are suitable for conversion to electric vehicles?

Choosing the right car for an electric conversion is key to ensuring optimal performance and efficiency. To start, lighter vehicles weighing between 2,000 to 3,000 pounds with manual transmissions are ideal candidates. This lighter weight maximizes the range of the electric motor, while manual transmissions are advantageous as they don’t drain power by idling like automatics do.

When it comes to body style, you’ll want a vehicle that can comfortably fit all the necessary batteries. Generally, compact and spacious cars, such as sedans or hatchbacks, are well-suited for conversions. These types typically offer enough room for battery placement without compromising weight distribution significantly.

Additionally, selecting a car with a solid body, a good-looking interior, and a functioning transmission is beneficial. The engine condition isn’t critical since it will be replaced during conversion. An electric conversion breathes new life into traditional vehicles, turning them into efficient and environmentally-friendly machines.

How long does it take to convert a gas-powered car to an electric vehicle?

The timeline for converting a gas-powered car to an electric vehicle (EV) can vary significantly depending on several factors. On average, this process takes around three to six months. However, it can sometimes extend beyond this timeframe based on specific requirements and complexities.

Factors Influencing Conversion Time:

1. Complexity of the Vehicle: Certain car models may require more intricate modifications, which can lengthen the conversion period.
2. Availability of Parts: Sourcing necessary components, such as batteries and electric motors, can affect how quickly the conversion is completed.
3. Experience of the Conversion Team: Skilled technicians with extensive experience may complete the task more efficiently, possibly shortening the timeline.
4. Customization Needs: If you desire additional custom features or enhancements, this can increase the time required for conversion.

Working with Professionals

Most conversion experts, including recognized third-party brands, generally suggest allocating ample time to ensure quality work. Therefore, when planning for a conversion, it’s wise to expect a timeline that could span several months, allowing for any unforeseen delays.

By understanding these factors, you can better anticipate the duration of transforming your traditional car into an eco-friendly electric vehicle.

How does an electric vehicle (EV) conversion work?

Converting to an Electric Vehicle: A Comprehensive Guide

Transitioning a vehicle from gas to electric involves a series of methodical steps that replace traditional combustion components with efficient electric counterparts. This process begins with the removal of the internal combustion engine, transmission, gas tank, and exhaust system. These are substituted with an electric motor, a controller, and an EV battery, forming the backbone of your new electric powertrain.

This type of conversion demands a blend of mechanical and electrical expertise, which is why many opt for professional services or comprehensive kits that guide them through the transformation.

Electric motors do not need to be running when the vehicle is stopped, and they generate significantly less heat than their internal-combustion-engine (ICE) counterparts. Most vehicles using ICEs rely on a serpentine or accessory belt to convert this idle energy to charge a 12V battery via an alternator, spin an A/C compressor, and run a power-steering pump. Furthermore, hot engine coolant is used to heat the cab via a heater core, and the negative pressure at the intake may be used to assist power braking or control other auxiliary functions.

When we convert a vehicle to an electric powertrain, we lose all these passive functions of the engine. How do we retain these creature comforts in a converted vehicle? Read on to find out!

12V Accessories

Rather than use an alternator to charge a 12V battery, we now use a component called a DC-DC converter to power the 12V system. The DC-DC converter steps down the high-voltage DC power stored in the battery pack (at 100V, 400V, or even 800V!) to low-voltage DC power to keep our 12V battery topped off. Then, all existing 12V components such as lights, wipers, stereos, and power windows, stay in the vehicle operating in the same way as they did before. Not only does this simplify the conversion process, it also keeps voltage in the EV accessory systems as low as possible, which results in a safer build.

DC-DC converters are available as stand-alone components or come packaged in a combined charge unit, which also includes on-board charger functions. DC-DC converters can be sourced in 1kW to 2.7kW power outputs, which can provide 73A to 197A of DC current to a 12V battery.

Heater

In an ICE-operated car, hot engine coolant is blown over the heater core, and that heated air is then distributed throughout the cab. In an EV, we replace hot engine coolant with HV DC power as the source of heat. In some cases, a ceramic electric heater replaces the heater core completely. In other cases, the existing heater core is reused by adding a small liquid heater to the heater core circuit. We use the HV DC power available in the batteries to keep current low and associated electrical conductors small for the same power output.

A/C

Very similarly to the heating system in an EV, the A/C compressor works much the same. The belt-driven A/C compressor is replaced with a HV A/C compressor to compress the refrigerant in your typical automotive A/C system. We can switch the A/C compressor off and on by using the compressor clutch signal that the belt-driven A/C compressor used or by using a CAN bus signal. Again, we use the HV battery as the power source to keep current low while providing plenty of power to cool the cab of the vehicle.

Power Steering

There are two primary ways to retain power steering in a converted vehicle. First, you can use an external electric power steering pump and then keep the existing rack-and-pinion. Alternatively, an electric power steering (EPS) can be used. EPS uses an electric motor to provide turn assistance to the steering system. The motor is activated by electronic sensors that detect the amount of steering lock being applied by the driver. This is used in both ICE and electric vehicles.

Power Brakes

There are three primary ways in an EV to retain power braking depending on the existing system present in the vehicle. First, a 12V vacuum pump can be added to the system to provide a source of negative pressure for vacuum boosted brakes. Secondly, hydroboost brakes can be utilized with the addition of a fluid pump. Lastly, we can add an electronic brake booster to add more stopping power.

Another thing to consider when talking about brakes in an EV is that most can use regenerative braking to slow down the vehicle. This means that under normal operation, less brake pressure is needed to slow down the vehicle. The added benefit of regenerative braking is that the kinetic energy of the moving vehicle can be converted back into electric energy to charge the battery and extend the range of the vehicle.

By implementing a few key component swaps, we are able to keep all the creature comforts that we are familiar with when switching from gas to electric powertrains. In many cases, the new accessories require less maintenance, creating an even more enjoyable ownership experience.

What options are available for someone without the necessary skills?

Individuals lacking the expertise for a DIY conversion can opt to hire specialized companies to perform the conversion. Alternatively, they can purchase conversion kits that include the necessary parts and offer step-by-step guidance.

What skills or expertise are required for an EV conversion?

Converting a vehicle to electric power demands significant mechanical and electrical expertise. It’s a complex process that typically requires specialized knowledge and skills.

What major components are replaced in an EV conversion?

An EV conversion involves swapping out the vehicle’s internal combustion engine, transmission, gas tank, and exhaust system. These components are replaced with an electric motor, a controller, and an EV battery to enable electric propulsion.

What are the benefits of converting a gas-powered car to an electric vehicle?

By implementing a few key component swaps, we are able to keep all the creature comforts that we are familiar with when switching from gas to electric powertrains. In many cases, the new accessories require less maintenance creating an even more enjoyable ownership experience.

Converting your gas-powered vehicle to an electric one offers a host of benefits that go beyond just the driving experience. First, consider the cost savings. The average driver in the United States spends between $150 to $200 monthly on gas. By switching to electric, you eliminate these fuel costs entirely, offering significant yearly savings.

Moreover, electric vehicles demand less upkeep. Say goodbye to regular oil changes and frequent engine repairs. With fewer moving parts and solid-state electronics, maintenance becomes a breeze, enhancing reliability and extending the lifespan of your vehicle’s components.

In terms of performance, expect your converted car to deliver a range of 60 to 80 miles on a single charge, with top speeds between 50 to 90 mph. Charging takes about six to 12 hours, depending on your setup. While the initial outlay includes electricity and eventual battery replacement every three to four years, these are manageable compared to the ongoing expenses of gas.

Ultimately, converting to electric not only preserves comfort and convenience but also adds value by enhancing the vehicle’s reliability and resale potential. Enjoy smoother rides, fewer breakdowns, and the peace of mind that comes with a more sustainable choice.