Mount Batteries and Controller

Now mount the controller and batteries. The controller which is used normally is same as the one used in forklifts. Place the batteries smartly by using the space appropriately. Trap and bracket them all in place.

Find an Apt Gasoline Car to Modify into an Electric Car

The first step is to look for an appropriate gasoline car that can be converted. Although the choice is completely yours, you should look for a car that is enough roomy and has manual transmission as the batteries will take lots of space to sit. Don't go for very old car, but it you like one then ensure that its assembly and gear transmission is intact.

Select a Battery Type

Choose the type of battery you require. There are many different options like high output sealed battery and lead acid, marine deep cycle battery. There are many more options to choose from, based on the type of electrolyte they utilize. They may be gelled, flooded and absorbed glass mat batteries. Do the math depending on the power/voltage you require and buy the batteries that are most suitable. Connect all the batteries you have bought in series.

Detach Unwanted Gasoline Car Components

Now starts the gasoline car's transplant operation. Detach the gas engine, gasoline tank, exhaust mechanism, catalytic converter, clutch and radiator and remove them.

Start Writing As Per Electric Circuit Diagram

Draw a correct circuit diagram, before doing the electric wiring. Keep all the manual transmissions intact and using adapter plate, attach a motor. Fix the motor using customized brackets.

Build Reduction Gear Set

Electric motor needs a reduction gear to customize the mechanism of gear for maximum efficiency. To achieve this you can either build a new tailored reduction gear or fix the current gear system permanently in first or the second gear.

Decide on Maximum Electrical Voltage Output

The next thing is to decide at what electrical voltage you want to run your car. The range can vary from 90 V to 190 V. The voltage amount will tell you the number of batteries that you will need. It will also determine the AC motor and controller specifications.

Wire the Installed Components

Now comes the wiring of the components. Connect the battery and controller with the motor as well as with each other using some high power cables. Install a separate motor if your original car had power steering mechanism.

Install Compressor, Heater and Air Conditioner

If your car has an air conditioner, then mount another motor to make its compressor work efficiently. A vacuum pump should be installed in order to operate its brake booster. A small water heater should also be installed in the heater's core to drive the car's heating mechanism.

Installation of DC to DC Converter and Wiring Accessories

DC to DC converter should be installed to power all accessory batteries. No need of gas gauge anymore. Just replace it with a suitable calibrated voltmeter that can slow down the charging level of your car's batteries. Connect accelerator pedal to controller with potentiometer in middle as connection link.