Our EV conversion series delved into EV conversions: what they are, why they exist, and how to do one. Though it was an introductory series and in no way a detailed how-to, I really hope we helped you get a better understanding of the process of converting a vehicle to EV, and what to consider before starting.

This topic is a very interesting one to me, personally, and I want to share my thoughts about doing a first EV conversion from the standpoint of a “student”, so to speak, since I have never done one myself.

What would MY first EV conversion look like?

I’m going to freestyle this section since I think “flowing” through it will make it much more enjoyable to me, than would following a strict process like we do at the OEM level. This is very important for me to emphasize: enjoy the process. It feels slightly contradictory since we spent months writing a whole series on how to design an EV conversion and prepare for the project using our SPARK method, which seems a bit square, orderly and at times “boring”. The idea behind SPARK, though, is to introduce you to many concepts, systems, and ideas about EVs in a systematic way. You can follow that system blindly, or you can grab bits and pieces at your own pace.

Now, have you ever thought about Harley-Davidson and the ethos behind their motorcycles? I’m not a Harley fanboy, I don’t own one, and I didn’t grow up dreaming of owning one, but I recently learned more about what most people love about them: simplicity. Nowadays the automotive industry has been plagued with all sorts of vehicles that seem bland: white SUVs with huge screens, blind spot monitoring and an engine so boring it hurts. These things are engineering marvels, but we have grown so accustomed to great engineering, powerful engines and comfortable rides that some of us have become bored with the offerings. The motorcycle industry, though slightly different in this regard, seems to be heading this way. Fuel injection, catalytic converters and even electrification have been taking over showrooms for years now, and though more capable, clean and reliable than ever before, some people want something else.

Enter simplicity. Harley-Davidson motorcycles, as described by purists, have always been “easy to work on, simple and dead-reliable”. What do these people mean? Well, you just have to look at what they were: a carbureted, air cooled, V-Twin engine that had tolerances so wide it could withstand abuse and neglect. Yeah, these motorcycles have a reputation of leaking oil and making more noise than power, vibrating themselves into a pile of chrome pieces in your garage, but we have to look at the idea behind their design.

You see, these machines had almost no fluff: engine, lights, starter, drivetrain. That’s it. Yeah, they weren’t the most efficient, quiet, refined or powerful machines, but they got the job done and they could be serviced anywhere. You never had to worry about an old school Harley “tripping a check engine light”, it ran or it didn’t. If it didn’t you serviced it, plain and simple. No dealer appointment, just a few beers and a wrench.

Why am I rambling about Harleys, the modern automotive industry, and boring engineering? Because I believe my first EV conversion, and maybe even yours, should aim to be the Harley of EV conversions: dead simple.

It’s easier to complete

I’m an automotive engineer, and I am a certified gasoline engine technician. This does not make me a SKILLED technician. I sometimes know what I’m doing, but most of the time I’m searching YouTube for video tutorials, googling shop manuals, and double checking the right-hand rule (righty tighty, lefty loosey?). This, combined with my overall knowledge and experience gives me the confidence to tackle SOME projects. But practice makes perfect, and I have 0 practice converting an ICE powered vehicle to EV.

Some of you will have much more experience, balls and knowledge than I do, and by all means, if you want your first EV conversion to be a dual Tesla swapped Corvette, go for it. And share it in the comments. But I assume most of you will want to attempt something easier.

Going all Harley on my first EV conversion allows me to focus on a few systems to get them right, and gives me the ability to finish a project in a shorter period, which I appreciate for my first attempt. I can upgrade later.

Simplicity

Cool, simplicity. What does that mean for an EV conversion? This section will try to convey what I’d look for in terms of components for my first conversion.

Worth noting is that I would focus on kits and/or brand-new components: I want to have the technical support I might need from the supplier, and I want to have as much technical documentation or previous experience from other builders that I can access online. I want to make this process as simple as possible so I can get the first one done the best way I can. Remember: my focus here is on the conversion process itself, not on the selection process, nor the process of adapting recycled components, or building my own battery packs. Just the conversion.

Motor

The simplest motor one can choose is a DC brushed motor. Sturdy and battle tested; this type of electric motor can do it all. All, but regenerative braking, that is. Harleys aren’t efficient either, so that’s a hit I’m willing to take.

These days, however, DC motors are not the cheapest systems, especially when dealing with brand-new components, or full conversion kits. AC motors have come a long way in the EV conversion market, and their controllers are very advanced, offering extensive customization and very useful features like regenerative braking.

Having said all of this, my first choice in today’s market would be a simple 3 phase AC motor. I won’t get into specific details about which particular product I’d choose since I haven’t done the full calculation, that might come at a later time. Just think of this: I want something that works right out of the box, has enough power, is air cooled, and doesn’t require a lot of maintenance.

Battery

I’d go for a small capacity battery pack, something that gives me a few miles of range, maybe 50 (I’ll define this in future articles). I would go for something coming from a kit too, that way I can guarantee the BMS included has been tested with the pack I choose, and I have some support from the supplier. I don’t have a preference for chemistry at this point; I’d even go NiMH if the price is right.

Charger

My OBCM would be something small, probably something around 3kW since my small battery pack and low range expectations don’t really require fast charging or multiple charges a day. This is a project for cruising around town every now and then, not my daily driver.

DC/DC Converter

My first conversion wouldn’t have AC nor cabin heat since I don’t want to deal with liquids or gases (coolant and/or refrigerant gas), so I wouldn’t need more than 1000W.

Auxiliary Systems

Brake vacuum pump and an electro-hydraulic steering pump would be the only auxiliary systems I’d consider. The electro-hydraulic steering pump would be optional, honestly, since I’m not aiming for comfort and that component adds complexity. If my donor vehicle has a hydraulic power steering system, and my budget allows for it, I’ll do it, otherwise I won’t sweat too much (pun intended, I’d definitely sweat without AC and power steering).

Stating the obvious

Honestly, I don’t think I added much to the discussion in terms of technical expertise, creativity or ground breaking advice in the previous paragraphs, but that wasn’t the intention. Today, my intention was to state the obvious: simplicity is king.

We live in a world where, for many people, technology seems more advanced the more complex it is. The harder it is to understand, the more some people value its impact to our society, environment, etcetera. Now, I don’t want to paint myself here as the #1 fan of simple technology; I make a living developing complex hybrid vehicles with many failure points and the simplicity of a space ship, and I love them. But truth be told: I think our society would benefit from admiring simplicity, more than screens, apps and overwhelming networks.

Many car enthusiasts today complain about manufacturers not selling fun, simple, lightweight vehicles with manual transmissions and an analog tachometer. But the overwhelming majority of people prefers a machine that thinks for them, a dealership that cares for it, and a driving experience that doesn’t feel like an activity to engage in. We are absorbed by our phones, our computers and our tasks so much that driving from work back home seems like an interruption to the never-ending flow of information from our devices to our conscious minds.

Driving should be an activity that requires attention, skill, and time. There was a time when moving from one place to another was done by walking through dangerous terrain, more like a survival skill than a pleasurable activity.

Have you ever heard of the saying about a dog slowing you down if you take them on a hike with you? “Maybe that’s the point” is what they say. So, here’s my thought: driving a machine that requires thought, skill, care and understanding might slow your day down.