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

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

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

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

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

We remove the cylinder head, crankcase, disconnect the clamps on the connecting rods and pull the pistons out of the cylinders.
How to convert a gasoline car into an electric car with minimal modifications

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

We remove the pump from the cylinder block.
How to convert a gasoline car into an electric car with minimal modifications

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

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

We place the prepared base for the drive on the upper plane of the cylinder block and fasten it with bolts.
How to convert a gasoline car into an electric car with minimal modifications

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

We install and fasten the electric motor.
How to convert a gasoline car into an electric car with minimal modifications

We put the timing belt toothed pulleys onto the crankshaft and drive shaft using keys and secure them with bolts.
How to convert a gasoline car into an electric car with minimal modifications

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

We connect the controller and lithium-ion battery to the electric motor.
How to convert a gasoline car into an electric car with minimal modifications

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

We put a belt on the pulleys, which should have good tension.
How to convert a gasoline car into an electric car with minimal modifications

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

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

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

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

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Comments (5)
  1. Konstantin
    #1 Konstantin Guests February 9, 2020 08:48
    7
    Hmmm...... Just 1 question - is it okay that the timing belt is not designed for the power of the engine? and what do we get in the ending? A toy for rides on a children's racetrack?
    1. Sergey K
      #2 Sergey K Visitors 25 April 2020 13:14
      2
      It will easily withstand three kilowatts, but there is another question - the engine in the car is at least 15 times more powerful, the gearbox may not provide the required speed, it will not provide traction on its own, and the range on such a battery...

      And most importantly - well, they redid it, drove through rural fields and roads, and what next? The traffic police will never register it, it will remain a toy
  2. Michael
    #3 Michael Guests 9 February 2020 18:39
    7
    What nonsense. How is the crankshaft lubricated?
  3. Guest Evgeniy
    #4 Guest Evgeniy Guests February 28, 2020 07:18
    0
    What about the vacuum seal? And if, without changing the design of the lower pulley, we make another gear and place the electric motor in front of the internal combustion engine or behind it, we get a hybrid car) plus if we make an electric motor with recuperation, you can charge the batteries while you are driving on gasoline.
  4. Rus
    #5 Rus Guests 27 October 2023 13:33
    1
    Why leave the cylinder block if you can connect the electric motor directly, because the crankshaft must be supplied with lubricant and without lubrication, firstly, the liners will not last long, and secondly, the electric motor is only 3 kilowatts and with the extra load in the form of ungreased liners and the mass of the crankshaft itself, it will be very difficult it’s not sweet, and secondly, over time, ungreased liners will simply jam and fail