On this page, I am keeping a pretty complete list of the tasks I came across in the build of my EV conversion. It’s intended to be a guide to someone else undertaking a similar project before they actually spend The Money, because this stuff is not always easy to come by, some of it does take practice/skill, and that means you may need to find others to do things for you.

An easy example is the adapter-plate between the electric motor and your donor-car. Pretty much every project needs one, pretty much every motor/car combination is different, and it takes some professional-grade machine-tools plus a thick sheet of aluminum to make a good one. If you have to pay someone, it’s not unusual to pay $300-$400 for the material, and another $500 to get the machining done.

If you live near a TechShop (now resurrected from bankruptcy as “The Shop”?) or similar Maker-space, it is very much worth it to check the place out. The equipment that comes with the membership is typically fine to do the EV work, and if it’s not your cup of tea then there’s always people around who will be glad to do things for you for a moderate rate. I am trying to talk to the bankruptcy administrator about reviving their Austin TX location, but so far no answer.

The pricing I’m putting in is for a bare-bones, simple unit. Tools are tools, and you can spend more for better, heavier, more professional versions until the sun comes up again. These prices will get you a tool that will last as long as the project, and maybe even a bit beyond that. Likewise, air compressors are a great thing and by spending the money on a compressor you save money on each power tool. For me the cordless tools have been way more convenient, but it’s a matter of preference.

 

For the mechanical part of the build

A 20-ton hydraulic shop-press, $250 or so

An engine hoist w/ load-leveler, $250 – $300

An impact gun (cordless), and more Nm/FtLbs is better. $175-$200. A matching set of impact-sockets is about $50