Inside the 1997 Subaru Sambar EV Conversion

Electrifying a 1997 Subaru Sambar with Repurposed Components

Some EV conversions stand out not because of their size, but because of their ingenuity. That’s exactly the case with this 1997 Subaru Sambar Super Deluxe Kei truck, now fully converted to electric by Legacy EV in collaboration with the Big Time YouTube channel.

But this build wasn’t just about modernizing a quirky Japanese micro-truck. It was a proof of concept for sustainable EV conversions—using repurposed components from a retired training bench to create a functional, emissions-free vehicle at a fraction of the usual cost. Now complete, the electrified Sambar is on the road, and it’s turning heads for all the right reasons.

Why the Subaru Sambar? A Kei Truck with Big Potential

Kei trucks like the Subaru Sambar have been a staple in Japan for decades—built to navigate tight city streets while offering impressive utility. More recently, they’ve gained popularity in the U.S. as compact, affordable alternatives to full-size pickups.

The truck delivers playful, controlled bursts of power—making for a hilariously fun driving experience.

The 1997 Sambar Super Deluxe originally came with a 658cc EN07 carbureted engine, producing a modest 39 horsepower and 39 lb-ft of torque. With a 5-speed manual transmission, a rear-engine layout, and switchable 4WD, it was built for efficiency—not excitement.

That’s all changed. Now powered by a Hyper9 electric motor, this little truck delivers 120 horsepower and 162 lb-ft of torque—more than three times its original output—while running cleaner and more efficiently than ever before.

Turning Old Parts into New Power—And a New Future for EV Education

Rather than starting with a brand-new EV powertrain, this project took a sustainability-first approach by repurposing a retired Legacy EV training bench. The motor, inverter, and supporting electronics still had plenty of life left. Instead of letting them go to waste, they were reintegrated into this fully functional build.

This approach didn’t just reduce costs—it also proved that second-life EV components can still deliver top-tier performance, making EV conversions more accessible for builders on a budget.

Beyond sustainability, the choice to repurpose bench components is also shaping the future of EV education. Every challenge solved and every design decision made is being documented and integrated into Legacy EV’s EV Build Fundamentals curriculum. Now instead of learning purely from theory, students will get real-world case studies based on this build.

Factory Look, Future Tech: Seamless EV Integration

With the original gas-powered drivetrain removed, extensive modifications were required to integrate the new electric motor and drivetrain setup while maintaining the truck’s stock appearance. The frame was reinforced to handle the additional weight of the battery pack and the higher torque output from the electric motor. A custom-fabricated crossmember was installed to secure the torque box, ensuring drivetrain stability under load. The front differential was repurposed and mounted in the rear, allowing the Hyper9 motor to drive the wheels through a 1.9:1 torque box, optimizing torque delivery and maintaining the truck’s original rear-engine layout.

Students will get real-world case studies based on this build.

The electrical system was designed for efficiency, longevity, and seamless integration. A 32.9kWh battery pack was installed under the truck bed, using 14 Kore Power modules in an alternating PN/NP configuration for optimal busbar placement. The aluminum battery box, fabricated using materials provided by Send Cut Send, was custom-designed for a secure and space-efficient fit. A Dilithium Designs BMS manages voltage, temperature, and overall battery health, ensuring safe operation. The inverter, mounted under the passenger floor, was secured with nutserts instead of bolts for easier future servicing. A TSM2500 3kW onboard charger and 1000W DC-DC converter were mounted on a custom plate in the original engine compartment, maintaining a clean and organized layout. The J1772 charge port was installed in the factory fuel filler location, allowing for a stock-like appearance while making charging convenient and discreet.

Performance has been dramatically improved compared to the original 39-horsepower gasoline engine. The Hyper9 motor now delivers 120 horsepower and 165 lb-ft of torque, making the truck far quicker and more responsive than its factory setup. Estimated range falls between 80-120 miles, depending on driving conditions, making it a practical urban vehicle while still maintaining Kei truck efficiency.

One of the biggest challenges in older EV swaps is retaining functional heating. Instead of designing a new system from scratch, the original heater box was modified to accommodate an HV heater core, which slid into the factory mounting points, preserving the stock airflow system while upgrading the heating functionality for electric operation.

While the powertrain has been completely transformed, everything outside of the drivetrain remains stock. From the suspension and brakes to the body and interior, the Sambar retains its original charm, now with modern performance and zero emissions.

Behind the Wheel: The Drive Experience

With the conversion fully completed, the Sambar has transformed from a quirky micro-truck into a surprisingly quick, fun-to-drive EV. The Hyper9 motor delivers instant torque, making acceleration smooth and effortless. With tires this skinny and this much torque on tap, rolling burnouts are effortless. Whether launching from a stop or rolling into the throttle, the truck delivers playful, controlled bursts of power—making for a hilariously fun driving experience.

Everyone who has driven the completed build walks away impressed—and more than a few want one of their own. The combination of compact size, impressive torque, and sustainable engineering makes this build one of the most unique EV swaps out there.

What This Build Means for EV Conversions

With the Sambar now on the road, this project showcases a blueprint for sustainable, cost-effective EV conversions. It demonstrates that second-life EV components can deliver high performance, Kei trucks are well-suited for electrification, and sustainability doesn’t mean sacrificing fun or functionality.

Following final tuning, the Big Time and Legacy EV teams have put the Sambar’s electric power to the test, documenting the entire build—from teardown to first drive—on their respective YouTube channels.

For those considering an EV conversion, this build proves it doesn’t have to be expensive or complex—just a matter of smart engineering and innovation. From a humble Kei truck to an emissions-free torque monster, the Sambar stands as proof that the future of electrified motoring can be just as exciting as it is sustainable.

Photos by Tim Cachelin