The best answer to the environmental pollution and ever-increasing fuel price is using electric cars. Many are adopting this new alternative energy system on their existing conventional vehicles, by outright conversion. At  dealership we were told that people who are now more in support of electric cars are converting their gasoline-powered, petrol or diesel cars to electric right in their own backyards and garages. Yes, it is that simple.

If you find that interesting take a look at the article below to get a glimpse of how it is done.

What it Needs

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A usual conversion from a conventional fuel car into an electric vehicle would need a few things that are listed below:

  1. It will need a DC controller and a DC motor.
  2. The voltage required for the conversion process could be anywhere between 96 volts and 192 volts.
  3. The amount of voltage you select will further control how many batteries should power the Used Cars, what kind of motor will suit the purpose and which controller will be used in the car. You will get most of these motors and controllers from the electric forklift industry.
  4. For conversion you will need a “donor vehicle” which will be used as the platform for the entire process of conversion.

The process of such conversion leaves plenty of scope to choose from the battery technology. The majority of these home conversions are done by using lead-acid batteries with several options:

  • Golf-cart batteries
  • Marine deep-cycle lead-acid batteries
  • High-performance sealed batteries
  • There can be flooded, gelled or AGM electrolyte batteries. Among them the Flooded batteries are of the lowest cost but also have the lowest peak power.

Once the selection for the motor, controller and batteries are made, the process of conversion can start.

Major Steps of Conversion

Here are the steps suggested by the  experts that you need to follow:

  • Start by removing the engine, exhaust system, gas tank, clutch and the radiator from the donor vehicle.
  • Now attach the adapter plate to the transmission before mounting the motor.
  • Now mount the controller.
  • Use some brackets to safely hold the batteries.
  • Now install the batteries, wire them as well as the motor to the controller with  a #00 measuring gauge welding cable.
  • If your car has power steering, it needs to be wired up too, and you need to mount an electric motor for its power steering pump. The same rule complies for the AC and power brakes.
  • Now install the charging system and a DC-to-DC converter to power the battery for accessories.
  • Install a volt meter to detect the state of battery charge.
  • Install potentiometers, attach them to the accelerator pedal and then connect it to the controller.
  • Install a large relay to connect and disconnect the battery to and from the controller. This relay helps in turning the car “on”. You need a relay to carry hundreds of amps breaking 96 to 300 DC volts without the need to hold an arc.
  • Now rewire the ignition switch to turn on all the new equipment.

Once the entire process of installation and testing is over, your new electric car will be ready to move.

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