Electric Vehicle Conversion Kits | Types of Kits and Process

Do you happen to be looking to give your car a futuristic style? If so, EV’s conversion kit may be useful to you. Whether you care deeply about it being green, want to save money, or happen to have a general interest in electric vehicles – electric conversion of your vehicle is always a sustainable and affordable option. Choosing the right kit will allow you to replace your beloved gas-powered car with a quiet and smooth electric car, which will also help the world and save you money in the process. Are you excited to learn how an EV conversion kit can unlock your vehicle’s potential? We’ve curated everything you need to know, so let’s jump right in.

What is an EV conversion kit? outward

An EV kit will allow you to convert a diesel or gasoline-powered vehicle into an electric vehicle. The kit usually contains the necessary components such as electric motor, battery pack, controller, charger, and everything else needed for the conversion. With the help of this kit, you can breathe new life into a car that originally ran on an internal combustion engine, turning it into a fully functional electric vehicle. This is an excellent option for those who want to support the environment but have fewer resources. Given the growing focus on sustainability, the popularity of electric vehicles is encouraging more and more people around the world to pursue them. Subsequently, the demand for electric vehicle conversion kits increased significantly.

Advantages of EV conversion kits

1. Reduced operating costs –The key benefit is reduced operating costs. Electric vehicles are cheaper to run than conventional ones due to reduced fuel and maintenance costs. Additionally, these conversion kits can extend the life of older vehicles, especially in countries with severe restrictions on older fossil fuel vehicles. These vehicles can be converted to electric power by converting their electric motors.
2. Environmentally friendly – Another major advantage of EV conversion is the environmental impact. Since electric cars have no fuel, they have a significantly smaller carbon footprint than (traditional cars), and they help reduce air pollution within cities. Using renewable energy for charging further adds to these environmental benefits. Additionally, there are fewer moving parts than traditional vehicles, resulting in less maintenance.

Types of EV conversion kits

• AC conversion kit: More efficient but expensive (Rs. 4 Lakhs to 10 Lakhs).
• DC conversion kit: More affordable (Rs. 2 Lakhs to Rs. 5 Lakhs).
• DIY conversion kit: Cost-effective option, but requires technical skills.

Here is the list of the best EV conversion kits in India.

1.Bharat Kit

Bharat Kits or Bharatmobi uses certified kits to convert hatchbacks and sedans like Maruti Suzuki Alto, Wagon R and Swift Dzire. These include batteries, motors, controllers, gearboxes and chargers. The customized LifePo4 battery provides 80 km range, 80 km/h speed in 5 hours and costs around Rs 5 lakh.

Key specs:

• Range: 80 kilometers
• Maximum speed: 80 km/h
• Electric motor: 15kW
• Battery type: LifePo4
• Charging time: up to 5 hours

2. E-Trio

E-TRIO converts internal combustion engine vehicles into electric vehicles with a focus on affordable models such as Maruti Suzuki Alto, Wagon R and Dzire. They offer two kits, EV-150 and EV-180, with prices starting at Rs 4 lakh. The conversion takes 48 hours and includes upgraded suspension.

Key specs:

• Battery type: Li-ion
• Range: up to 180 kilometers
• Conversion time: 48 hours

3. Bosch electronic axis

It has 96% efficiency, scalable output from 50 kW to 300 kW, and operates at 400V/800V. Integration reduces extra parts and may reduce costs.

Key specs:

• Output: 50-300 kW
• Torque: 1,000-5,000 nm
• Movement speed: 16,000-18,500 rpm
• Weight: ~90kg
• Voltage: 400V/800V

4. North Motorsports

Northway Motorsport specializes in developing electric vehicle powertrains and conversion kits for vehicles, including light commercial vehicles such as the Tata Ace. They offer popular kits for models like Maruti Suzuki Dzire.

their Drive EZ Dzire’s kit offers a range of 120 kilometers and a charging time of 5-6 hours. For longer range travel is The kit offers up to 250 kilometers but takes up to 10 hours to charge. The cost of the kit depends on the vehicle, with the Touring EZ kit available for some cars at Rs 14.50 lakh

Key specs:

• Maximum speed: 200 km/h
• Range: up to 300 kilometers

5. dolly motor

Haryana-based Doreal Motors converts petrol and diesel vehicles into electric motors. They offer conversion kits for models like Maruti Suzuki 800 and Hyundai Grand I10. The cost ranges from Rs 300,000 to Rs 900,000.

Key specs:

• Maximum speed: 115 km/h
• Range: up to 320 kilometers
• Battery: 40 kWh
• Motor: 50 kW

Key considerations before converting your car to electric

1. Legal requirements

In India, ARAI approved kits are allowed, but ARAI approved kits must be used. Without these kits, your converted vehicle will not be legally re-registered through the RTO, making the conversion illegal. Choose a kit that complies with necessary regulations to avoid legal issues.

2. Vehicle compatibility

Not every vehicle can be converted to electric. Check whether your car’s structure and platform are suitable for modification. Major brands offer off-the-shelf kits, but unique vehicles may require custom solutions, which can be more expensive.

3. Battery and performance considerations

This is the component of battery conversion, with various options such as solid-state, lithium-ion, etc. all offering their advantages and disadvantages. It’s important to work closely with the manufacturer to find the right battery and motor setup to suit your driving style and requirements.

Conversion steps

Step 1: Remove Internal Combustion Engine Components

Internal Combustion Engine Disassembly: The first step involves extracting the internal combustion engine system. This process involves disassembling the engine, which includes the fuel tank, starter, muffler, radiator, and even the exhaust system. Remove other components: Any parts associated with a traditional sputter engine, including fuel lines, are unnecessary and will be removed.

Step 2: Install the Motor

Electric Motor: The center of the conversion is embedded in the electric motor. As a result, the size and type of vehicle determines the type of electric motor selected. The conventional sputtering engine is replaced by an electric motor mounted on the drive shaft after the gearbox.

Step 3: Install the battery pack

Battery Placement: The location of the electric motor with the battery pack is determined by the vehicle type. The bag is secured in sufficient places, and the number of batteries depends on the size of the car, its range of motion, and the space inside it. Battery Type: Efficient batteries, primarily lithium-ion, with long life and high energy density.

Step 4: Incorporate the Power Controller

Assembly Instructions: The power controller is a very important component as it manages the supply of electrical current from the battery to the electric motor. It is also responsible for the correct amount received by the motor.

Step 5: Modify and test

Upgrade the suspension and other hardware to support the extra weight of the battery. Brakes and axles modified for smooth operation. After conversion, re-register the vehicle at the Regional Transport Office (RTO) to obtain a new registration certificate. Test vehicles to ensure correct performance and efficiency.

Most importantly: is it worth the money and trouble?

The bottom line is that if you are concerned about sustainability and long-term cost savings, then although it is a bit daunting as an investment, it will prove to be fruitful in the long run. It all depends on you, how you weigh your investment against the environment and long-term financial gains.

check it out Electric Cars: Why Consider One?