There are many variables that determine range including size and weight of vehicle, number of batteries, capacity of batteries, age of batteries, air temperature, driving habits, terrain and the quality of your charger. If your daily range requirement is less than 30 miles, you should get reasonable service from your batteries, three years, some report even longer. 

I want to tell you up front that the biggest challenge you will face as an EV owner is keeping the batteries healthy for long life.  Lead acid batteries are the most affordable for do-it-yourself conversion.  However, they are also the least robust and very temperamental.  Make sure you read my section on Battery Service Life and my most recent evaluation that I do every 6 months.

If your desire is strong, you need the following:

Basic Skills and Knowledge

To complete the conversion, you need some basic skills and knowledge.  You may have those skills and knowledge or you can team up with someone who has skills that you do not.  You will also need to do some research and reading to increase your knowledge.

• Mechanical – you are accustomed to working on cars.

• Electrical – you have an understanding of basic wiring and electricity.

• Welding – you have basic welding skills or know someone who does.

• Troubleshooting – you have experience troubleshooting problems in vehicles.

Be aware that most conversions are done by handymen and backyard mechanics.  You don't have to be an engineer to do this.  All of the components to make the conversion are available off the shelf and there is plenty of help available - not only from this Web site but from many component suppliers and others who have converted their vehicles.  Remember, team up with friends who have different skills than you.  Most likely, they will be happy to help.

Location

You need a place to work – a place that is dry and can be secured at the end of the day.  The location may be your garage or a separate workshop that is dedicated to the project.

Time

Plan on the conversion process taking many months, depending on the amount of time each day that you can dedicate to it.

Money

Establish a budget before you begin.  Decide what components you must buy and those that you can make.  Use the ‘Bill of Materials’ section to help estimate cost.  It will cost you anywhere from $7000 to $10,000 depending on the type of conversion.  You should be able to get a nice donor vehicle for $2500 or less.

Tools (Get Tools)

• Wide assortment of hand tools: socket sets, box-end and open-end wrenches, cable cutter, pliers and screwdrivers, wire cutter/stripper, wire terminal crimper

• Overhead winch or hydraulic hoist on wheels

For metal work:

• Welder and supplies

• 14” cut-off saw

• Bench grinder

• 4 ½” angle grinder

• Drill press

• Electric hand drill and wide assortment of bits

• Punches, chisels, files, hammer

• Acetylene cutting torch (nice to have but not essential)

Misc. Supplies

• Service Manual for your donor vehicle

• Variety of terminal ends for #16 through #12 wire

• Assortment of hook-up wire

• Assortment of 5/16” hardware (bolts, nuts, washers)

• Lots of paper towels and hand cleaner

• Bandages and salve for cuts and burns