Across Canada and the United States, there's a growing interest in electric vehicles (EVs). For some, there's also a growing curiosity about the conversion process that turns gas and diesel cars into EVs. Although EV conversion is complex, this brief guide can help. This rewarding but technically demanding process is a good project for someone who owns a gas vehicle, wants an electric vehicle, and has the skills to get the work done.

Key Takeaways:

• While it is possible to convert a gas or diesel vehicle to electric, this process requires technical knowledge and careful planning.
• Costs can vary depending on the type of vehicle, the customization, and the materials used.
• Training in EV systems can help with the EV conversion process.
• One of the most difficult things to do when converting a car to an EV is choosing a battery and placing it in the vehicle. The selection of the battery must be done carefully.

Understanding the Basics of EV Conversion

During a conversion, the vehicle's internal combustion engine is removed, and an electric motor and battery pack are installed. The engine and battery pack must be compatible with the vehicle so that it delivers enough power to move the vehicle. The engine and battery must also fit without adding too much weight. For this reason, some vehicles are easier to convert than others.

Lightweight vehicles, sedans, and even classic cars can be logical choices for EV conversion because they have simple mechanical layouts. Bigger and more powerful vehicles can be converted, but they require a larger motor and batteries.

1. Battery Selection and Range Expectations

The battery is the most critical component in any electric vehicle. When choosing the right battery, know your range goals as well as weight and space constraints. There are trade-offs between cost and range that can affect your future satisfaction with the conversion.

Climate has a significant impact on battery performance, and cold weather can reduce range. If you're in the northern US or much of Canada, the climate in your area will affect which battery you choose.

2. Cost and Budget Planning

The typical cost of a conversion in Canada is a minimum of $15,000 CAD and may cost as much as $25,000 CAD with labor. In the US, the conversion starts at $10,000. How much you spend on this project depends on the cost of the battery pack, electric motor, controller, and labor. Doing the conversion yourself saves thousands.

3. Safety and Technical Complexity

High-voltage systems come with risks. Proper installation and wiring are important, and if you're performing the installation yourself, you'll need technical knowledge of electrical systems, diagnostics, and troubleshooting. Without proper training, you could do lasting damage to your vehicle and even injure yourself.

4. Regulations and Legal Considerations

In addition to the technical considerations, there are also legal considerations for anyone who is considering an EV conversion. For example, while EV conversion is legal in the United States, removing the catalytic converter from a vehicle is not — unless the person performing the conversion follows the carve out of the Clean Air Act, which allows a vehicle to be converted to a clean alternative fuel.

In Canada, your vehicle may require a safety inspection due to the major changes made to the car. The details of this inspection vary by province.

5. Vehicle Compatibility and Design Constraints

Not all vehicles are equally suitable for conversion. While deciding whether to convert your vehicle, consider its weight and size, space for batteries, your budget, and goals.

Older vehicles can be easier to convert in some ways, but their components are often worn, and some aspects of the vehicle may require replacement — even parts that are not directly related to the conversion itself. Newer vehicles may be in better condition for conversion, but they have very complex systems that can present challenges.

Either way, proper planning for your conversion is critical for the success of the project.

Can You Do It On Your Own?

If you're planning to convert your own gas vehicle to an electric vehicle, you'll need mechanical and electrical skills as well as knowledge of system configuration. If you're an EV technician with EV technician training, the task will be easier. Having hands-on experience and guided training can increase your confidence and the knowledge required to take on this type of conversion.

Is EV Conversion Worth It?

EV conversion can be very rewarding — and even practical — if you have the skills and enjoy complex EV projects. This type of conversion is most worthwhile if the labor can be done DIY, as this can save thousands of dollars.

If you have a technical interest and training, you may be a good candidate for converting your vehicle. In addition to the training and skills, you'll also need confidence. If you've been through a good training program, you should have what it takes to work on EVs and tackle challenging projects.

Learn the Fundamentals of EV Technology

Are you seeking a career with high demand and long-term growth potential? EV Technician Training allows you to earn a certificate as an EV Technician. To learn more, speak to a George Brown Polytechnic Program Coordinator today at 1-888-553-5333, or email us at [email protected].