What Does it Take to Turn Any Vehicle into an EV? We Ask Seth Leitman, Author of “Build Your Own Electric Vehicle”
by Eric Leech, New York, NY 
on 12.22.08
Book Cover: McGraw-Hill
Electric vehicles are a hot topic right now, but the problem is there really isn't much to choose from other than a handful of hybrids and NEVs (neighborhood electric vehicles). But did you know that for the price of a new, bottom of the barrel, no thrills or frills subcompact car, you could turn just about any vehicle into an EV?
We had the opportunity to speak with Seth Leitman, consulting editor of the Green Guru Guides, founder of Green Living Guy, and author of Build Your Own Electric Vehicle, and asked him exactly how someone with minimal armchair mechanical knowledge, ability, and tools could fabricate their own EV. We think you'll be happily surprised by some of his answers...
Treehugger: Seth, could you tell us a bit about your background?
Seth Leitman: “It all really started with my Masters Degree in Comparative International Development at the Rockefeller College of Public Affairs and Policy (Part of SUNY Albany). My focus was international lending practices through the IMF and how it affected energy/environmental projects funded by the World Bank. This degree made understand that there was a need to change how those institutions coordinate efforts to develop innovative energy efficiency programs and projects.
Afterward, I worked in the NYS Senate for a year and then worked for the New York State Energy Research and Development Authority (NYSERDA). There, I worked on green buildings (when everyone use to joke and ask, Hey is that the paint on the wall?). I also managed the Clean Fuel Bus Program for NY that funded over $100 million for alternative fueled vehicle buses. It was then that I began to appreciate electric drive with the Lockheed Martin hybrid electric drive trains that went into the buses in Manhattan. I really thought it was cool that off all the other alt fuels, by using hybrid buses were basically cleaner than any other alternative fueled bus.
Once my wife and I were having our first child, we moved to Westchester and I worked for the New York Power Authority (NYPA) which basically powers New York Subways, Metro North and Long Island Railroad trains which are all electric. While at NYPA, we teamed with many partners to create the NYPA/TH!NK Clean Commute Program TM which leased 100 electric vehicles in the NY Metro area; right after 9/11. I told someone recently that 9/11 gave me a real understanding to reduce our reliance on oil. I was so excited when the program was covered by USA Today, Associated Press, Reuters, New York Times, CNN, Good Morning America, the Today Show, and others. Today, this is still the largest electric vehicle station car program worldwide.
TH: What made you decide to write this book? What was the greatest driving force in the decision?
SL: Well, it was my editor, Just Bass. You see, I was asked to re-write this second edition of the book. The first edition was published by McGraw-Hill in 1993. Since then there have been changes to the technology available for conversions. There has also been some history for electric cars (as in the movie Who Killed The Electric Car?). I said yes after she first emailed me to ask.
TH: Could you give our readers a run down of exactly how an electric car is built from scratch?
SL: If I could be straightforward here, I am not a mechanic and never claimed to be. There is a source directory in the back of people that can help the billions of people like me that have a problem charging their own dead battery. So even though I have ridden many electric cars and used charging stations to charge them, I do have a problem with dead car batteries.
Seriously, what I have learned from this experience is that you take the engine out of the car and keep the transmission. Some of the conversion guys I know like the idea to connect the motor and adapter plate to the transmission. Someone recently noted to me though that the Tesla electric car doesn't even have a transmission/gear related system. However, I personally can conceptualize the motor to the transmission.
Anyway, you add a charger, electric motor, controller (controls speed and range) and batteries. Of course, there are gears, switches, pentometers (like a throttle), converters and other things that make an electric car work... For me, that is when I call the mechanic.
TH: Are there any cars in particular that make a good base model from which to start from?
SL: Volkswagen Bug, Ford Ranger, Honda Civic are really great. Also, there is a Nissan conversion in the book that is really cool too.
TH: How long would it take the typical armchair mechanic to accomplish such a task?
SL: About 120 hours or some people have done it in two weeks.
TH: About how much would it cost to build a basic model?
SL: If you have an old car ($3,000), parts ($6,500) and batteries ($3,000), plus labor ($3,000). $15,000 - $18,000. That can get you about 80-100 miles.
TH: Are there any parts that would be particularly difficult to come across?
SL:Great question, I want to show you both sides to these two hurdles.”
1) Controllers
Controllers are hard due to the 2000 amp controller from Zilla was recently put on hold till about February - March. Also, the AC propulsion controllers are the best out there but more expensive than Zilla or other brands.
However, there are controllers that are easier to get that would work just as fine and are readily available. The issue with 2000 amp controllers is you get speed and hard torque. 650 amp ones get you a 60 - 65 mile per hour top speed (maybe at that). However, most commutes don't need more than that, right?
Picture of the electric motor controller and charger placed in the back of a Porsche 911. Components for the Porsche thanks to Paul Liddle at EV Porsche.
Look, I know that speed is important to the American essence of a car 0-60 in nothing. I get it. To get to 65 mph will be quicker with electric cars due to only a controller and motor working with batteries to push that car. Yet people want 100 miles per hour and speed and range. At this time, it comes with a price, but it shouldn't have to with our economy and the need for electric cars.
2) Batteries
That is the biggest one out there. You see to get 300 miles you need lithium iron phosphate or lithium iron for between $20-$40k (depending on the vendor and specs). On the other side, that price is down. In addition, there are companies that have lead acid and generate the range of the nickel based technology (120-150 miles). Furthermore, there is technology that can get us 600 miles on a charge. Those batteries are not out there but could come one day if need.
Right now though we can get good electric cars on the road with good lead acid batteries until the price for better batteries comes down. There are good signs that cost is coming down. Just look at power electronics (cell phones, power tools). They have advanced technologies that can soon be in cars!!
TH: What kinds of experience and tools would someone need to accomplish this build?
SL: The person who is a car tinkerer, do-It-yourself type or mechanic should do it. Also, the person that just wants to take a car and make it electric also has a tool: the will.
TH: If one of readers was interested in this project, what kinds of things would you recommend they do in order to get started?
SL:Read the source directory in the back after they are done reading the book. There are conversion companies, specialists, parts, Electric Auto Association clubs, other organizations and things to learn about electric cars. That will give you the greatest tools to build an electric vehicle.
TH: Do you have any similar subject books or seminars on the horizon that you could tell us about?
SL: Based on the current success of the book, I am now a consulting editor to McGraw-Hill on a line of books called the Green Guru Guides. They are also Do-It-Yourself cool, easy style books to Green yourself and your home. In the first round of books, I am also writing a book called Build Your Own Plug-in Hybrid Electric Vehicle to be released in 2009.
TH: Just out of curiosity, did you notice an up sweep in book sales as the price of gas was rising earlier in the year?
SL: Some would think that. Since oil is such a volatile commodity, we see constant sales of the book. Coming back full circle, we now see the lowest oil prices today and we saw the highest oil prices in July-August. Now, we have oil production cuts being implemented by OPEC. Plus, they now have a Memorandum of Understanding (MOU) from Russia to join in on the cuts. The big three factors always regarding electric cars that could possibly help the Big Three (I hope) get out of this mess:
1) The Environment and Climate Change
We all know about how that is a constant.
2) Energy Costs
Electric cars cost pennies to charge. Also, for hopefully another opportunity to talk about electric cars with you is Vehicle-to-Grid (V2G). This is when the batteries (energy storage) of your car become a reverse meter on your energy costs; when you charge it at the train, bus stations or work during the day.
Those times when you are plugged in, the utilities take energy from your car at 15 minute intervals; then they recharge the car again. Now you get a credit on your energy bill and pay hopefully next to nothing for power. What an amazing cut in energy costs for everyone!
3) Economic Issues Facing us Today
Car company bailouts should inevitably be directed (and I believe can) toward every car being electric drive of some sort of another. While I am an EV purist and will always be, this move would give an immediate boost for green jobs, real jobs. This could only help our discussion for automotive jobs, green jobs and the entire industry.
More on electric vehicles
Electric Vehicles: To Drive or Not to Drive?
Plug-in Hybrid and Electric Vehicle Owners Struggle to Find Places to Charge Up
28 States To Get Smartlet Electric Vehicle Charging Station Distributors, Entire US + Canada Early Next Year
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I'm just wondering why he seems to have ruled out hydrogen as an alternative fuel? The reason I ask is that I am concerned about the impact of millions of electric cars on gas and coal burning electric plants. Are we going to get these electric plants off of gas and coal?
Hello,
This is Seth. While hydrogen is good, it is not as efficient as a fuel as electric.
Also, what does hydrogen create; electricity.
Therefore, a fuel cell car is an electric car.
As for our powerplant mix, as the book states, electric cars are the cleanest even if coal is the only fuel.
We need to increase our renewable electric load, decrease our polluting electric load and then we have a pollution free, oil free solution.
@Colleen: Do you realize it takes the same power plants and more energy to actually get Hydrogen in a usable form?
Hydrogen is not an energy source, there are no stockpiles or undergound caverns full of Hydrogen
It's an energy 'carrier' and more analogous to a battery. You need to separate it from water or other sources.
This is confusing for people because Fossil fuels are both an energy source and an energy carrier. Hydrogen is NOT like this.
Best case scenario with existing technology is clean energy production (wind/solar/thermal) and electric vehicles driven by batteries. Future better scenarios may include fusion power plants and fuel cells or ultracapaciors (EESTOR), but they are not realistic TODAY.
Mr.Leitman.
What about engines that run on hydrogen as a combustible fuel? do you think those will be a good alternative fuel source? I know a few friends in college who converted a o.35L diesel engine to run on hydrogen with minor modifications. It wasn't perfect, but it did the job.
Sid,
Thank you for the question.
I support converting a car to anything that is alt fuel but personally I believe that an all electric car is the more fuel efficient way to go.
Hydrogen is not as fuel efficient as battery power and also there is little or no infrastructure to support hydrogen.
Electric cars, however, there are 110 outlets all over the place and they are zero tailpipe emissions.
Why bother to mention AC Propulsion in a discussion of do-it-yourself electric car conversions? They have never sold a controller to an individual, and probably never will. So the relative price of their controller could not be less relevant.
Has anyone on this site seen the film of the Hindenburg Disaster? The Air Ship Hindenburg was filled with hydrogen gas to give it lift. A spark from an unknown source caused the air ship to explode and burn, killing lots of people.
http://video.google.com/videosearch?client=firefox-a&rls=org.mozilla:en-US:official&channel=s&hl=en&q=hindenburg&um=1&ie=UTF-8&ei=g_mESffyJom4sAO3_vy3DQ&sa=X&oi=video_result_group&resnum=4&ct=title#
I'm no rocket scientist, but that looks an awful lot like a source of fuel to me. I do know for a fact that the chemical composition of water is dihydrogenmonoxide or more commonly H2O, 2 molecules of hydrogen and 1 molecule of oxygen. It's true, there aren't caves filled with hydrogen waiting to be discovered.
Does anyone have any idea just how much water there is on this planet? I inflated a balloon with hydrogen gas in my high school chemistry class, using nothing but a six volt dry cell battery, a flask, a rubber stopper, some tubing, a sprinkle of salt, 2 pieces of wire, some cheap electrodes and tap water.
Jacob, thank you for an explanation of a scientific principle that is in no way based in science. Jacob, just because crude oil exists out there and hydrogen doesn't doesn't mean hydrogen is worse. we still expend energy to convert it to usable gasoline. and we could use things like wind and solar power to separate H2 from water, although I'm willing to bet that scientists will find a much more effective way to produce hydrogen in the coming years. anyway, the real reason I am writing this comment is to point out that electric cars, (even the DIY variety) are not the miracle cure we've all been waiting for (hint: waiting for instead of actively trying to find one ourselves...). lets first consider the batteries: the making of lithium phosphate cells alone consumes enormous amounts of energy, not to mention all the toxic pollutants that the process creates. now the motors: do you ever think how they get all that copper to make the windings? Copper is mined from ore, which means mining huge amounts of rock for very little yield. the impacts of this are incredible. first, the actual mining machine (which consume approximately 100 gallons of gas a MINUTE) has to dig up literally thousands of tone of ore, which is then transported in giant trucks (using even more large quantities of gasoline and diesel) to huge plants that use amazing amounts of power and generate large amounts of toxic waste to make a comparatively minuscule amount of copper. and just think how much of that stuff is used in an EV... the mining industry used 5% of all the electricity produced in the U.S. last year, and we don't get it all from here. please PLEASE spread the word!!!!!!! I can't tell this to everybody myself! and consider all the impacts of what you do befor you do it!
these are meant to go after my other post before i signed up on typepad. anyway, here are links to some sites talking about the impacts of copper mining.
http://www.resolutioncopper.com/res/environment/52.html
http://www.mineralresourcesforum.org/aboute.htm
like this very much email me update to this article
I live in Minnesota and we get to 40 below zero in the winter. How do EV's perform in the cold and how would we heat the vehicle for passengers?
Hi Seth, I live out in the country, and in the northern part of the USA. Does your Electric conversion guide have power to weight ratio or take in account steep grades and cold weather? Most of my rural roads speed limits are a min of 45 mph , therefore, the need for 0-50 in at least 7 seconds, is this also in your text ? I know , purchase your book , and find out how to build, But if your conversion is in an ideal flat and 70 deg weather running no lights or radio, what are we achieving here? Thank you very much Seth. I happen to have a Ford that does Not miss many stations now, So I am very interested in this. D Hutch WA State
About the copper mining, hydrogen etc. Yes and if you run your car by burning hydrogen directly you still have all the mining for all the metals that your motor is made of........as well as all the electricity consumption that went into producing your hydrogen........which is actually more electricity then you get out of the hydrogen in energy whether you burn it in internal combustion, or generat electricity from it using fuel cells.....it is an energy loser......more energy used then what you get back........can't you guys understand that.
At the end of the day the only sustainable age in human history is the Stone Age. This is because no matter what resource we use.........we will run out.......think not......what about wind.......solar........yeah.........what about all the metals, plastics etc that we need to make panels, turbines etc. In the end, the human race will deplete everything and have nothing but stone, and wood to make things out of, and our own hands and energy from our muscles to make it with.
While electric cars are not the whole answer to our transport needs they can be a very good one.
First all of the copper can be recycled. An electric motor can last millions of miles vs the 150,000 miles that a gasoline engine lasts (unless you've got a really good car that lasts twice that and an owner that really cares for it right).
Batteries like the NiMH batteries that Chevron has shelved and lead acid batteries can be recycled many, many times. This is one reason I'm a little down on Lithium based batteries. Not as recyclable.
We're mining for coal and drilling for oil and yet still arguing that EVs are somehow worse. EVs can be better, they are easier to maintain, cleaner locally, and can run on electricity produced from any number of sources - not just coal. They can be charged with wind, wave action, solar, nukes... Internal combustion engines run on gasoline or diesel, they require frequent lubrication maintenance, frequent repair (relative to multi-million mile electric motors) and then there is the long list of extras like exhaust systems, fuel systems, and so on that are missing from EVs. Gasoline powered vehicles don't generally recapture energy while slowing down assuming the vehicle isn't a hybrid.
What does the human race need to do? A bicycle or walking based village system where most of what that group of humans needs is produced locally. Until we adjust our expectations and wants to fit something like a village type society, at least we could adopt more efficient types of transport like EVs.
I'm going to take a look at this book and see what it has to offer. My biggest barrier to EV ownership is the initial investment. Ditto for the solar roof I want. I have the tools and welding machine. What I need is a book that spells out in detail brands and capabilities of all the major components of an EV. I'll have a rolling donor vehicle here in the next few years as one of our high mileage cars wears out it's engine. The rest of the cars are in good shape and I'd prefer to convert it vs replacing the gasoline engine or buying a new car.
While we can argue that it takes fossil fuels to build the components, like the batteries, etc., there is also fossil fuels consumed to produce a gasoline engine. At this point in technology, we cannot completely eliminate fossil fuels in the production of anything. The common denominator in all is the cost of production, therefore, the only true measure is total cost of production and use over a reasonalbe time period.
My question for the author is, has there been any research to recapture the kinetic energy of the car in motion (i.e. rolling wheels, braking, etc.) to recharge the batteries while the car is in motion?
To answer the question below, yes the book Build Your Own Electric Vehicle, 2nd Edition does have a power to weight ratio. As for colder weather, we include what appropriate percentages to take into account. However, most of the batteries we recommend (Nickel Metal Hydride) do not have a weather related problem.
Finally, if a vehicle is charged overnight, you will be good to go on a charge for the delay with those speeds.
Enjoy the Ford conversion!!
Seth
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Hi Seth, I live out in the country, and in the northern part of the USA. Does your Electric conversion guide have power to weight ratio or take in account steep grades and cold weather? Most of my rural roads speed limits are a min of 45 mph , therefore, the need for 0-50 in at least 7 seconds, is this also in your text ? I know , purchase your book , and find out how to build, But if your conversion is in an ideal flat and 70 deg weather running no lights or radio, what are we achieving here? Thank you very much Seth. I happen to have a Ford that does Not miss many stations now, So I am very interested in this. D Hutch WA State