I’ve taking a 2004 Corvette, removed the fenders and hood and grafted on 1953 Corvette body panels with modifications. I’ve invested about 18 months on this project and the body is about 70% complete for a rough prototype. The next step is to make the passenger side match the driver’s side. After the body is complete, the next step is to remove the engine and replace it with an electric motor and batteries. The final stage would be to create a custom tubular frame. Long term goal is to build these cars to sell. I am currently creating a 3D model of the car and plan to use the CNC router to make molds. Fiberglass body panels will be made from the molds. I am wondering if any other DMS members are interested in participating in this project. I have pictures but I do not see how to add them here. Here is a link:
I get a 404 Not Found
Sounds like an interesting project.
To post pics from google photos to here now I just copy the image (right click, copy image), then just paste (ctrl+v) into the box here where you are typing the post. The link you posted is not a public url, you would have to click the share icon then get shareable link, then post that link, but I think just pasting the image here is easier.
Here’s a car similar to what I am after (this is a later model Corvette, dual headlights, different grill, different rear end):
I’d like to help with the electric conversion part. I’ve always wanted to do an EV conversion but never had the money for it.
So Mitch, have you done much research on building an electric car? I’ve done some, enough to discover that you can buy the parts off the shelf. The challenge becomes repackaging them for a car in which a “kit” doesn’t already exist (case with a C5 Corvette). One big challenge is that there is not space to put the number of batteries required in one spot. Therefore they have to be broken up into separate “clusters” that are distributed around the car. Ideally you would want to strategically distribute these to optimize weight distribution.
The other challenge is the choice of AC or DC motors. DC drivetrains are significantly cheaper than AC ones. I was quoted around $25k for the parts to do a DC drivetrain (battery alone is $20k+). A AC drivetrain with similar power would cost at least twice that (the Zombie 222 site claims 3x cost). While AC is a better long term option, I don’t want to spend that much on the first prototype.
Because of their high power to cost ratio, DC drivetrains are typically used for electric drag racing. The weight of a Corvette (around 3200 lbs) makes it a less than ideal platform but this route makes for the most economical “electric sports car”.
One option that recently surfaced is that old Nissan Leafs (2010) are now selling for around $10k. While the end result would be so under-powered that the word “sports car” couldn’t be used to describe the results, it would probably be the fastest and cheapest route to a “sporty LOOKING electric car”.
One other issue is that the donor car has an automatic transmission, which is less than ideal. This means that either aftermarket transmission controller needs to be used or the factory transmission controller needs to be hacked. Since there will also be issues with other computer controlled functions, it would be ideal if someone could figure out how to hack the factory computer control systems.
Not sure if you have heard of the Zombie 222 but here is some info:
http://www.zombie222.com/buying.html
This is where I am with the planning for the electric conversion. Have you done any research at a deeper level than this? I only have enough money to pick one option so I am trying to figure out which one is best. There is still a LOT of research that needs to be done in this area and I will be tied up with the body and mechanical details for the near future. So, how deep do you want to get into the planning of the electric car conversion and when do you want to start?
probably about 8 years ago I wanted to do a conversion but I didn’t have the money for the motor, controllers, and batteries. I would have done a conversion for a VW Type 1 beetle or ghia because I think there’s plenty of adapter plates and conversions already for an ADC motor and probably would have deepcycle leadacid batteries and Curtis controller. It was a while ago I looked this up, I think lithium battery packs with built in BMS are an affordable option now.
There are some really nice conversion kits now with DC-DC converters, vaccum pumps, regen AC controllers, etc Karmann Ghia hyper 9 120v 26.5kW EV Conversion Kit, AC Motor, Regen Braking, 1955-1974, EV West - Electric Vehicle Parts, Components, EVSE Charging Stations, Electric Car Conversion Kits
Honestly, I don’t think an EV conversion would be really drivable in DFW with limited range. The Nissan Leaf is definitely enticing if I could afford another car, even with <100mile range.
Mitch wrote: “Honestly, I don’t think an EV conversion would be really drivable in DFW with limited range”. Why do you think that Mitch? I only drive 24 miles a day round trip so I could get by with a pretty short range. The place I used to work had charging stations but I don’t think my current place does. By the time I actually start selling these cars, battery technology (and cost) should come down significantly. It has already come down 50% in the last year or two. When I first started looking back then, the battery alone was going to cost $40k.
I had already looked at EV West. Unfortunately, they don’t make a kit for my car. Plus, those kits are far too under-powered for my goals. With the equipment we have available at Makerspace, it wouldn’t be difficult to design and build the required mounts and adapters.