Breathing New Life into Classics: Electric Vehicle Conversions
Electric vehicle (EV) conversions have been around for decades. The initial surge in interest occurred during the environmental and energy crises of the 1970s and 80s. Today, modern EVs are boosting demand for classic car conversions.
Several specialist workshops now offer these conversions, providing options for those seeking a unique electric car or those keen to electrify their classic vehicles. One such workshop, Electrogusto in Sydney, is leading the charge.
Nick Cummins, a partner at Electrogusto, describes himself as a modern-day hot rodder. He blends his passion for vintage cars with the reliability of electric powertrains, making classic cars more accessible and enjoyable to drive.
Converting a petrol car to electric power isn’t as simple as swapping out the engine and fuel tank. Cummins explains that “There’s also a hundred other different components that work in that ecosystem to make the car function, and also be safe and modern. So that’s where it becomes quite complex.”
What types of cars get converted?
Conversions typically begin with a deep evaluation of the customer’s needs and the car itself. This includes desired power, range requirements, and cosmetic upgrades such as repainting or interior customization.
Most conversions focus on classic or special cars with significant sentimental value. Owners seek to continue driving these vehicles for years, even passing them down to future generations.
These conversions can be costly, averaging around $100,000. Some vehicles currently undergoing conversion include a 1971 Porsche 911, an ex-army Land Rover Perentie, and a 1940s Fiat Topolino. There is also a Citroën HY van, which, once converted, will serve gelato at events.
Different Choices for Motors and Batteries
After understanding the car and the customer’s goals, Electrogusto identifies the best components for the conversion.
They carefully assess the car’s characteristics, including power output, braking system, weight distribution, to ensure the final product meets road-use requirements.
Electrogusto uses different types of electric motors, depending on the car’s axle design and available space. Motors from Tesla, Nissan Leaf, or brands like NetGain HyPer 9 are frequently used.
Motor selection also affects battery pack choices and optimal weight distribution. Most Electrogusto conversions offer a range of about 200 kilometers, ample for weekend driving or use as a second car.
Both new and repurposed batteries are utilized. China Aviation Lithium Battery (CALB) batteries are sourced from Lithium Power and supplied in modules. Tesla battery modules are also sometimes repurposed. However, with the growing size and structural integration of newer Tesla batteries, Electrogusto is exploring other battery sources.
Cummins explains, “Then we work out the weight distribution for the battery packs. We’ll scan a car in 3D, put it into CAD and mechanical engineers design battery boxes, brackets, motor mounts, everything to install all this stuff. It’s very often a giant jigsaw puzzle to find space for everything.”
What Else Needs to Be Changed or Upgraded?
With EV conversions, space is a premium. This is different from the design of a new electric vehicle, with its purpose-built chassis.
The conversion process necessitates extensive planning, collaboration with independent engineers, plus compliance with registration requirements.
Depending on the car’s condition and the owner’s preferences, body panels may be restored. The chassis and braking systems may require reinforcement and upgrades for safety.
Usually, the original gearbox is retained, with an adapter connecting it to the electric motor. If the electric motor’s power output significantly exceeds the original petrol engine’s, the gearbox might be replaced with a simple gear reduction setup.
Power output from the motor can be easily reduced if needed. When the original gearbox is kept, it can be locked into 3rd gear, eliminating the need for the clutch. New buttons on the dashboard handle drive, neutral, and reverse gears.
There’s a trade-off between keeping things original and simplifying. Modifying fewer parts reduces the certification and registration effort, which is another key consideration.
The Build Process Begins
Once planning is complete, the build phase starts. Electrogusto prefers to use OEM parts wherever possible.
The complexity of the process means novel solutions are often needed, such as a new 12V wiring loom and, in some instances, a whole new 12V system.
Braking systems, power steering, an electric accelerator pedal, and new parking brakes are frequently upgraded as well.
A demister is legally required for vehicle registration, and since original cars used engine heat, a new 12V heating system with custom ductwork is implemented.
How Long Does a Conversion Take?
The entire conversion project typically takes around 6 months.
The end result is a classically styled car that is not only a head-turner but also fun and simple to drive.
Maintenance is reduced. Owners save time and have more opportunities to enjoy their cars.
Near Electrogusto’s workshop, the converted Volkswagen Type 3 squareback wagon receives plenty of compliments from passersby.
Converted electric cars incorporate aspects of modern EVs, like adjustable regenerative braking with one-pedal driving modes. Often, the interior is beautifully restored, with upgraded gauges that are sometimes hidden behind a panel.
Future of EV Conversions
Cummins predicts the conversion market will stay niche but grow as more people want to preserve their classic cars due to the difficulty in finding replacement parts or mechanics with the necessary expertise.
Future emissions regulations may also push more people toward conversions.
Vehicle-to-home (V2H) and vehicle-to-grid (V2G) capabilities are future goals for Electrogusto, making the battery packs useful when the cars are parked.
If you are keen about converting your car, reach out to Electrogusto, or check them out at Everything Electric in Sydney.
