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While late-model, nonrunning bargains are great, avoid the problem situations Avoid buying off-brand, too old, abused, dirty, or rusty chassis The parts and labor that you have to add to them to bring them up to the level of normal used models makes them no bargain The salesperson might offer you that used 1957 Mingus for only $50, but where do you get the parts for it
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Dirt and rust are OK in moderation but too much of anything is too much If you can t tell what kind of engine it is because you can t see it in the engine compartment, pass on this choice You don t want to spend as much time cleaning as you do converting or pay someone else to do it, only to find that essential parts you thought were present under the dirt are either in poor condition or not present at all Rust is rust, and what you can t see is the worst of it How can you put your best EV foot forward in a rust bucket for a chassis Don t do it; pass on this choice in favor of a rust-free vehicle or one with minimal rust
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Keep Your Needs List Handy
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Regardless of which vehicle you choose for conversion, you want to feel good about your ability to convert it before you leave the lot If it s too small and/or cramped to fit all the electrical parts let alone the batteries you know you have a problem Or if it s very dirty, greasy, or rusty, you might want to think twice Here s a short checklist to keep in mind when buying: Weight With 120 volts and a 22 hp series DC motor, 4,000 to 5,000 lbs is about the upper limit On the other hand, the same components will give you blistering performance and substantially more range in a 2,000- to 3,000-lb vehicle Weight is everything in EVs decide carefully Aerodynamic Drag You can tweak the nose and tail of your vehicle to produce less drag and/or turbulence, but what you see before you buy it is basically what you ve got Choose wisely and aerodynamically Rolling Resistance Special EV tires are still expensive, so look for a nice set of used radials and pump them up hard Drivetrain You don t want an automatic; a 4- or 5-speed manual will do nicely, and front wheel drive typically gives you more room for mounting batteries Avoid 8- and 6-cylinders in favor of 4-cylinders, and choose the smallest, lightest engine/drivetrain combinations Avoid heavy duty anything or 4-wheel drive Electrical System Pass on air conditioning, electric windows, and any power accessories Size Will everything you want to put in (batteries, motor, controller, and charger) have room to fit How easy will it be to do the wiring Age and Condition These determine whether you can get parts for it, and how easy it is to restore it to a condition fit to serve as your car
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Buy or Borrow the Manuals
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Manuals are invaluable If possible, seek them out to read about any hidden problems before you buy the vehicle After you own it, don t spend hours finding out if the redstriped or the green-striped wire goes to dashboard terminal block number 3; just flip to the appropriate schematic in the manual and locate it in minutes Component disassembly is easy when you learn that you must always disengage bolt number 2 in a clockwise direction before turning bolt number 1 in a counterclockwise direction, etc Believe me, these are labor savers
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5:
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Chassis and Design
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Sell Unused Engine Parts
Somebody somewhere wants that 4-cylinder engine you are removing from your EV chassis for their car or for scrap metal Emblazon this above your workbench area before the removed parts begin to accumulate dust or crowd out all other items from your garage First, make a few phone calls to place want ads; then call dealers and junk yards If no cash consideration is offered, see if you can trade the parts for something of value Do all of this early, before you are in the middle of your conversion Nothing worse than stubbing your toe on an engine block while nonchalantly going for your voltmeter
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