Electric Car Conversion: Genius or Foolhardy?

This post, part of a series we're running all about electric cars, was written by William R. Harris from HowStuffWorks.com.

Back in the 1980s, when the Commodore 64 defined the home PC market, I remember writing a program to catalog my album (yes, album) collection. Today, no one would indulge in such an exercise. It makes no sense to write a program from scratch when you can buy an off-the-shelf database or spreadsheet application that does the same job more effectively.

People who want to own an electric car face a similar dilemma. They can either convert their internal-combustion car -- in essence, build an electric car -- or buy a ready-made electric car from one of several manufacturers. For some, spending $35,000 to $40,000 for a brand-new battery-powered car feels like an insurmountable obstacle, even with state and federal tax credits. But is converting an existing gas-powered vehicle really a better option?

To answer this question, we need to cover the economics. Conversions start at about $13,000 for cars and $16,000 for trucks equipped with golf-cart batteries. Upgrade the battery, however, and the costs go up appreciably. Lithium batteries -- the most advanced power source for electric cars -- can add an extra $12,000. That takes a car conversion to $25,000, which is about $8,000 less than the asking price for a Nissan LEAF.

The economics seem to favor conversions, but you have to ask yourself if you have the fortitude to take on the work and how you value your time. A typical conversion is a serious overhaul. First, you have to make sure the vehicle getting the makeover is appropriate. Cars weighing less than 3,000 pounds (1,360 kilograms) are a better choice because the conversion is going to add even more weight. And, of course, newer cars that don't need to be repaired offer a better starting point than run-down clunkers.

Once you select a vehicle, you have to remove the vehicle's internal combustion engine and install new brakes and bearings. Then you have to make room for the batteries. This requires some serious welding and fabrication, which can transform a four-seater into a two-seater. Finally, you'll need a fresh-air system to make sure no harmful battery fumes accumulate in the cabin. If you're doing the work yourself, the whole process can take several months or even a couple of years.

You're not done when you finish the car, either. You also have to evaluate your home's electrical system -- the source of "fuel" for your newly converted car -- to see if it can handle the extra load. Companies like Nissan have partners that provide this service and will install dedicated home chargers for $2,200.

So, how smart is an electric-car conversion? If you're handy, patient and want the satisfaction of keeping another used car out of the salvage yard, then it's very smart. But as more ready-to-drive electric cars become available and prices fall, building an electric car will make as much sense as creating a spreadsheet from scratch when many powerful and reasonably priced applications already exist to do the same job.