Electrifying the Past: The Rise of EV Conversions
Converting classic cars to run on electricity isn’t a new concept. Enthusiasts have been electrifying vehicles for decades, with interest spiking during the energy crises of the 1970s and 80s. This early enthusiasm led to the formation of organizations like the Australian Electric Vehicle Association (AEVA) in 1973. Today, the growing popularity of electric vehicles is fueling a resurgence of interest in EV conversions, leading to the establishment of dedicated workshops offering bespoke electric cars and eco-friendly options for classic car owners.
Recently, The Driven visited Electrogusto, a Sydney-based workshop specializing in these conversions. Partner Nick Cummins, a self-described “modern-day hot rodder,” shared insights into the intricate process of transforming a classic internal combustion engine (ICE) car into a battery-electric vehicle.
“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,” Nick explains. It’s more than just swapping a petrol engine for an electric motor and a fuel tank for batteries.
The Conversion Process: From Classic to Electric
The conversion process begins with understanding the customer’s vision and the car itself. Questions are asked to determine the desired power, range, desired aesthetic, and whether the owner wants luxury features such as heated seats. Most conversions center around classic or special cars that have sentimental value, allowing owners to continue driving their beloved vehicles for years to come.
Because of the labor involved, the average conversion can cost around $100,000. Notable projects currently underway at Electrogusto include a 1971 Porsche 911, an ex-army Land Rover Perentie, a 1940s Fiat Topolino, and a Citroën HY van destined to become a mobile gelato vendor.
Different choices for electric motors and batteries
Electrogusto’s experts meticulously gather information about each car—its power output, braking system, weight, and weight distribution—to ensure the final product meets road-use certification standards. This is required for registration. The choice of electric motor is dictated by the car’s axle type and available space, with motors sourced from old Tesla or Nissan Leaf vehicles, as well as the US-made NetGain HyPer 9 or Chinese brands.
Motor selection determines the available space for battery packs and their necessary weight distribution. Most vehicles converted by Electrogusto are equipped with a range of approximately 200 km, which satisfies most owners who primarily use their vehicles on weekends or as a second car. Similar to the electric motors, several different brands of new or repurposed batteries are used. CALB (China Aviation Lithium Battery) batteries are sourced from Lithium Power in WA, supplied in modules about the size of a shoe box which can be grouped together and positioned within the space available. Tesla batteries are sometimes repurposed from wrecks, after being tested by suppliers to be safe and functioning correctly. However, Tesla battery modules are growing in size and newer vehicles have structural battery packs that cannot be taken apart easily for reuse, so different sources will need to be found in future.
“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,” says Nick.
Beyond the Engine: System Upgrades and Modifications
Space constraints are significant in EV conversions. Unlike the luxury of a ground-up EV design with a skateboard chassis, conversions require careful planning and collaboration with independent engineers. Depending on the vehicle’s condition and the customer’s preferences, body panels may be restored. Additional work may be necessary to fortify the chassis and upgrade the braking system.
In most cases, the electric motor is connected to the original gearbox via an adapter. If the new motor’s power exceeds the gearbox’s capacity, the gearbox is removed and replaced with a simpler gear reduction setup. It is also possible to reduce the motor’s output power if desired. Cars with an original gearbox can be left in 3rd gear. The clutch is not need, and drive, neutral, and reverse gears can be selected with new buttons installed on the dashboard.
A tradeoff exists between simplifying things and balancing the desire to keep things original. Fewer parts modified along the way also means there is less work to certify and register the car at the end, so this is another factor to consider.
The Build Process: Precision and Ingenuity
Once planning is complete, the build process begins. Electrogusto prioritizes OEM parts wherever possible, leveraging the safety and reliability proven through extensive vehicle manufacturer testing. As Nick mentioned, unexpected challenges arise, demanding innovative solutions. These can include a new 12V wiring loom and, sometimes, an entirely new 12V system. Braking systems, power steering, electric accelerator pedals, and new parking brakes are also often replaced.
Regulations require a demister for road legality. Since older cars used engine or exhaust waste heat for windscreen heating, a new 12V heating system is fitted, often requiring custom 3D-printed ductwork.
The Final Product: A Fusion of Past and Future
The entire conversion process typically takes around six months. The outcome is a classic car that elicits appreciation on the road and offers the joy of simple, fun driving. Maintenance requirements are also significantly reduced compared to the original components, giving owners more time enjoying their cars.
On the road, these converted electric cars incorporate modern EV features, such as regenerative braking and one-pedal driving. Interiors are often beautifully restored to maintain the original aesthetic, sometimes keeping new gauges hidden behind a panel accessible with a button press.
The Future of EV Conversions
Looking ahead, Nick believes the EV conversion market will likely remain a niche but is expected to grow as more owners seek to preserve their classic cars, especially with the increasing difficulty of finding replacement parts and knowledgeable mechanics. Future emissions regulations could incentivize more conversions. Electrogusto is also exploring implementing vehicle-to-home (V2H) and vehicle-to-grid (V2G) capabilities, making their battery packs useful even when parked.
If you want to convert your car, you can contact Electrogusto or visit their workshop in Petersham, Sydney. They’ll also exhibit vehicles at Everything Electric in Sydney between March 7 and March 9, 2025.
