Easy Electric Car Conversions

In very basic terms, electric car conversion is all about removing the ICE (internal combustion engine)from your car, and replacing it with an electric motor and associated parts. While it might seem like a daunting task, it is really not that hard if you like working on cars and have the right guide. Hopefully the information contained here will help you on your way to fossil fuel independence.

Electric car conversions are easier than you might think. Once you have built your electric car you no longer have to worry about oil changes or other
gasoline engine type maintenance. All of the problems associated with gas engines are history. Here are some of the benefits and savings you will see by converting your own car to electric.

1. No more costly gas fillups
2. Charge your electric car on pennies a day
3. No longer spew harmfull emissions.
4. You'll be doing your part in cleaning the environment.
5. Get a tax credit from Uncle Sam
6. No more costly tuneups or smog checks

Electric car conversions work best when you pick the right car. You need to choose wisely, as the overall performance of your conversion will be determined by the size and weight. Remember that you will be carrying extra weight (batteries) so you need to use a car that is not only light, but also can endure the added pounds.

You will want to pick a small car so that you get the maximum distance of your batteries, between charges.

The next step is to make sure the car you choose has a manual transmission. The reason for this is because automatic transmissions have to operate at a very high rev, compared to the electric motor. The automatic has to be turning fast enough to pump the fluid inside the transmission correctly. The car you decide on should look decent. Obviously you don't want one full of rust, or is all dented up. The car needs to be road worthy and safe. You may need to pass a vehicle inspection after the conversion to electric has taken place. Hopefully you can find a car without the motor, this should make the price cheaper and you won't have to hassle with removing the old motor.

Here is a list of small vehicles that have been converted to electric successfully

Datsun 280
Dodge Colt and Neon
Datsun Truck
Ford Festiva and Escort
Ford Probe
Ford Ranger
Geo Metro and Storm
Isuzu
Mazda 3000 Series
Mitsubishi Tredia
Porsche 911
Toyota Corolla
Toyota Tacoma
Volkswagen Beetle

For more info on sources of donor vehicles and other electric car conversion details you can check out the guide I used to put my electric 95 Geo Metro together here Electric car conversions guide

Choosing the proper battery for your electric car
conversion is the key to getting the best performance. You will need to use deep cycle batteries, as this type of battery is designed for high current and slow discharge. Not to be confused with a standard car starting battery, which only provides high current for brief amounts of time. The most popular battery type for electric cars is the traditional lead acid battery, and there are three major types.

1. Flooded battery

2. Gel Batteries

3. AGM Batteries

The Flooded or "wet" cell is by far the most available
lead acid battery. If they are the type with removable
caps, then you have to periodically check and refill the cells. All batteries will produce hydrogen and oxygen when recharging, and you will lose a certain amount of water during this process unless the battery is of the sealed type ( maintenance free) The benefits of using this type of battery is usually the cost, they are the least expensive. They are also less sensitive to overcharging as compared to the other types of cells. However they can also be prone to collecting deposits on the plates if they are left in a discharged state for extended periods. This is called sulphanation, due to the sulphate crystal
deposits that can form on the plates. There are devices known as "desulphators" which as their name implies can eliminate the deposits and basically rejuvenate an old battery back to usable condition. The flooded battery must also be kept charged up. A deep discharge without a quick recharge will cause the battery to lose its capacity. Flooded cells will perform best if the discharge is kept to only about 50% between charges, this will give you the most energy throughput.

The second type of lead acid batteries are called Gel Batteries. In this battery the acid has been suspended in a Silica gel, which prevents it from spilling any acid if its case becomes damaged. This also allows the battery to be put in un-conventional positions, on its side for example, without any worry about acid leakage. The disadvantage to this type of battery is the charging rate. They have to be charged at a much lower rate than the other lead acid batteries, otherwise too much gas is produced internally and cell damage will occur. They require a special type of charger which is current limited so they don't become overcharged. Overcharging the gel battery will cause voids to develop in the cells, thereby limiting the total capacity. This type of battery has been used in AC conversions and has performed well, as long as proper charging precautions are taken into consideration.

The third type of lead acid batteries are the AGM batteries. AGM stands for absorbed glass mat. In these batteries the acid is soaked into a glass fiber mat to about 95% saturation. Since the acid is contained in the mat,leakage is not a factor. This is also a sealed battery, so you don't have to periodically check the level of the cells. The hydrogen and oxygen produced when charging, get recombined back into water during the charge, so this battery is very efficient. Any conventional lead acid battery charger will work with this battery, and the AGM batteries have a real low self-discharge rate, so they can sustain a charge even with no charging for a long period of time. Really the only dis-advantage to this battery is the price. A typical AGM battery is 2-3 times more expensive than a flooded battery.

Your choice of the electric car conversion whether it is DC or AC, is going to be the deciding factor in your battery choice. If you choose to do a DC conversion you will want to use the 6 volt battery to make up your battery pack, simply because they provide the most amps for the size and weight. If you go with an AC conversion, you will want to use the 12 volt battery, as you need the extra voltage to make up the higher voltage requirement of the
controller. Which ever voltage type you choose, the flooded lead acid is the best choice from a cost/power ratio. As battery technology continues to
progress however, you could soon see the day when AGM batteries become as cost effective as the traditional flooded lead acid battery. Free Electric car conversion guide