How to convert a gasoline car into an electric car with minimal modifications

The main trend in the modern automotive industry is the use of electric drives in production vehicles. It is impossible to organize conveyor production of cars in a garage, but even a novice mechanic can assemble one electric car. As a test sample we use a small car with a worn-out engine, with a working transmission and gearbox.

Components, materials and tools

Car modifications can be carried out in a garage or any flat area, preferably with an inspection hole. To carry out work on re-equipping a passenger car, we will need the following:

• Set of plumbing tools: wrenches, screwdrivers and pliers.
  
• Drilling machine.
  
• Steel plate 15-20 mm thick.
  
• Electric motor with operating voltage 60 V, power 3 kW.
  
• Controller (60 V, 4 kW) and 40 Ah lithium-ion battery with operating voltage 60 V.

You will also need fasteners: bolts, nuts and washers for mounting the electric drive.

Procedure for manufacturing an electric car

We begin the re-equipment of the car with its partial disassembly, for which we remove the hood, headlights, radiator grille and the radiator itself, as well as the top bar.


The actual alteration work is carried out in the following sequence:
We unscrew the mounting bolts, disconnect the exhaust manifold and dismantle the block head, and also unscrew the timing belt pulley.


We remove the cylinder head, crankcase, disconnect the clamps on the connecting rods and pull the pistons out of the cylinders.


We remove the pump from the cylinder block.

We take a steel plate, make markings for its fastening using cylinder head bolts, and on a machine we drill holes for them and for the seats of the electric motor.


We place the prepared base for the drive on the upper plane of the cylinder block and fasten it with bolts.


We install and fasten the electric motor.

We put the timing belt toothed pulleys onto the crankshaft and drive shaft using keys and secure them with bolts.


We connect the controller and lithium-ion battery to the electric motor.


We put a belt on the pulleys, which should have good tension.

We secure the cable from the gas pedal using a screw clamp tightened on a screwdriver handle. The latter, in turn, is installed on the axis of the voltage regulator, such that acting on it causes a change in the position of the regulator. As a result, the speed of the electric vehicle changes.


The conversion of a machine with an internal combustion engine to an electric motor drive has been completed.Driving the car is no different from a regular vehicle: we sit behind the wheel, turn on the voltage to the electric motor, squeeze the clutch, engage the gear, and slowly release the pedal and add gas. The car starts smoothly and picks up speed well; tests on a flat section of the road with a hard surface reached 50 km/h.

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