Most of those who contemplate to set up a small electric car conversion manufacturing line for carrying out semi-skilled conversion jobs will never make any headway beyond conceptual stage, even though it is not at all a difficult job to do. The major reason for this is the prohibitively high costs involved in such jobs.

For example, in order to convert a superior model car fitted with entirely new components will cost a huge amount of money, around $5000 to $10,000 that too exclusive of labor costs. Nevertheless, there are a number of methods to cut down on these costs.

Here are several steps involved in establishing a small electric car conversion business.

1. To start with, one should float a LLC (LTD) company and draw up a detailed plan with specific time schedule. Once a feasibility report is ready, he should apply for a business loan from the bank. If the project is viable, subject to bank confirming the credit worthiness of the borrower, it is not difficult to obtain a bank loan.

In several countries, one can apply for a bank loans online on the internet. If the documentation is complete and satisfies the bank’s requirements, one can easily get the loan and start the operations within a week.

2. The next step in setting up the car conversion line of business is to purchase all the electric car parts in bulk quantities. One can save a lot of money when purchasing electric car motors, controllers and various accessories in large quantities by arranging with the supplier bulk discounts as well as price discounts.

Apart from this, there will be considerable saving in transport costs. All these factors will result in substantial reduction in the overall cost per car.

3. Final step is to modernize and organize the process to minimize time and labor costs. It is important to use the same type of vehicle for each conversion so that only one set of battery racks needs to be designed and is set up in a specific manner.

Suppose one tries to convert five different cars, it requires five different sets of battery racks and along with that there will be variety of problems to deal with, ultimately spending a lot of time and money. Although it is possible to take up more than one type of car at a time for conversion, it involves a lot of time and money on account of additional labor costs.

The best way to cut down time by at least 50% is to rationalize and repeat each step from making gear box adapters to installing five sets of controllers. This way conversion of each car can be completed at the same time for delivery to the market.

This facilitates selling all the converted cars in one lot, thereby saving costs on advertisement and sales promotion. There is currently a lot of demand for electric cars and it is likely to increase every time the gasoline prices go up. In this scenario, there is no need for spending money on advertising for electric cars.

The major car manufacturers making electric cars charge very high prices for electric cars and this automatically creates more business for converted electric cars. The success of this venture depends upon how fast gasoline-powered cars are converted to electric cars.

It is very important to convert the cars at the shortest time possible in order to increase productivity and maximize profits. The cars such as the Nissan Leaf will be selling for above $40,000 when it is marketed next year.

If the batteries are bought outright instead of leasing, one could convert at least two cars for $40,000 with the same range of 100 miles as the 2011 Nissan For those who have taken up this business for the first time may find electric car conversion job a daunting task.

Nevertheless, with a good planning, dedication and hard work, one can reap lots of profits in electric car conversion business.

The difference between a deep cycle battery and a cranking battery is quite obvious. The output from the first one is a steady flow of current over a long time, whereas the second one produces a high-level of current for a short spell, normally to crank a motor to start.

There are also dual purpose batteries like AGM batteries which exhibit marine cranking amperes, cold cranking amperes and reserve capacity data. Generally the motors installed on the homemade electric car will exhibit the cranking amperes required for the motor in the starting stage.

The battery of a wet cell operates through a system of regular service by opening and adding water, when the water contents get evaporated during the heat up process. The cells in the battery should remain immersed in water-acid-liquid as otherwise; the battery may dry up and stop operation.

As the acid does not evaporate during the heat up process but the water does, the water level should be maintained through a regular service. In the wet cells, acid water mixture may sometimes run out and any eventual leakage of acid may cause several damages. Therefore the sealed, leak proof wet cell batteries are preferable, as they do not require regular water service.

Leak proof batteries like Gel Cell and AGM batteries can be stored in any position. The AGM battery always has an edge over gel-cell and wet-cell batteries. The battery load itself will indicate the exact type of deep cycle battery needed.

A cranking battery is much ideal for operation, if it is used for starting and maintaining a few electrical functions. A deep cycle battery is useful for powering trolling motor and electronic devices. But the AGM batteries rule supreme in DIY electric cars, as they are sealed and can be stored anywhere.

Two such batteries can also be joined and put in position to draw more power if they are of the same amp. If the amp differs; one of the batteries joined can get damaged easily. Another important factor is hooking of the batteries. Two batteries of the same volts are hooked together by joining the positive to the positive terminal and negative to the negative terminal, which is called parallel wiring.

By doing so the volt remains the same while ampere output doubles. Similarly, by joining the positive to negatives of the other battery and vice-versa as in a flash light, the volts may double but the ampere will be equal to that of one battery. This is called series wiring.

Normally the ampere rating of a 6V battery is higher than a 12V battery of the same size. By series wiring of two 6 volts batteries, 12V power with higher amperage is achievable, unlike a single 12V battery that will have lesser amperage.

Hence as a safe measure, more number of low volt batteries are used in golf carts etc. Charging of batteries too has different options out of which, automatic multistage system is most ideal.

Ruling out the possibility of an over charge. Though a car battery can be used in an EV, a deep cycle battery is superior service as they are manufactured to match the load requirement of a high torque electric motor. They are mostly duel purpose batteries, sealed and made leak proof.

AGM batteries provide high output of power with low internal resistance compared to other batteries. That is why they are widely in use by the DIY electric car enthusiasts.

Many people when taken away from the main power supply depend upon the good battery and charging set. They do not understand the characteristic of the battery which they are using in their caravan/RV/camper trailer and have no knowledge about the power supplied by the battery and its duration.

The worst is that when the battery gets completely drained out and suffers an irreparable damage and cannot be charged again. This blog post deals with certain aspects and will provide information about the use of the battery and its maintenance.

Different Types Of Battery In The Market

One has to clearly demarcate and understand that there are three types of battery which are commonly used. These are wet cell starter batteries, deep cycle batteries and a variation of deep cycle that is AGM. It is very important to understand the differences because each one has specific purpose and the functions.

The starter battery is the one which we commonly under the bonnet of the vehicle and provides strong current to the starter motor for short time. Due to the requirement the manufacturing technique is different than the deep cycle battery otherwise its life will get shortened as the plates get deteriorate fast.

Deep cycle battery is the one which is not designed for providing short heavy loads but is designed for occasional discharge below 50% threshold; this is the rule of the thumb to maintain long life of the battery.

Deep cycle battery can be a wet cell also but the manufacturing is done with the electrolyte which is more of a gel which can be sealed easily. Sometimes these batteries are also called maintenance free batteries. Maintenance free does not mean you will use these batteries the way you want it. Wet cell deep cycle batteries perform better in hotter climate.

Most batteries are manufactured in such a way that they can perform better in the places which has cool climate. AGM, Absorbed Glass Mat, is the best battery when you are camping because of its performance and long life. AGM batteries are quite expensive but even if it is expensive it has many advantages to offer.

These batteries have been designed in such a way that it can absorb the occasional discharge below 50% level, even some cases it is even 20%, but the basic point is that all the batteries need recharging. The batteries suffer maximum damage when these are not properly charged and are allowed to get discharged.

AGM has another property that it gets charged up faster and have capacity to take more charge which is very close to 100%. These batteries are very strong and can tolerate wear and tear as these were originally designed for the use of military. As these batteries are sealed, you can easily store these batteries in your car or a caravan or practically in all possible places.

Even if these batteries are left unattended, you can charge the batteries again faster as these batteries being very tough do not deteriorate faster or lose the efficiency.

Those on a long trip or on an excursion away from the main electric power source need a dependable battery without the need for recharging on the way. Many people normally use the battery provided in their caravans, recreation vehicles or ‘camper trailers’ without understanding the features of the battery such as how much electric current it can generate and how long the charge lasts.

Sometimes these batteries get drained out completely with little chance for repairs. People usually going out on excursions or undertaking long day journeys should be aware of different types of batteries, type of battery required for such trips and something about battery maintenance.

The batteries installed in vehicles are ordinary starter batteries designed to generate short, huge bursts of electric current to start the engine of the vehicle and after that they get fully discharged and are recharged while driving the vehicles. This type of battery is however not suitable as substitute for providing steady power for long hours without the need to recharge frequently.

A deep cycle battery is ideal for such purposes. It provides constant power over a long period without getting completely discharged. A deep cycle battery is a sealed lead-acid battery or valve regulated lead acid battery (VRLA).

VRLA batteries are further divided into absorbed glass mat battery (AGM) and gel or gel cell battery. While the life of a typical automotive starter battery is generally up to 4 years, a normal deep cycle battery lasts up to 6 to 8 years and an absorbed glass mat battery is even more durable, lasting up to 10 years.

However, the longevity depends on how well the battery is used and maintained. The capacity of a battery is expressed in Ampere hours. Suppose one has 100 Ampere hour battery and uses only one light. This consumes only 1 amp from the battery. Theoretically, the light remains switched on for 100 hours.

However, in practical terms, it will be safer for the battery if the light is used only for 50 hours. If someone wants to compute how long the battery is likely to carry on, it is necessary to prepare a list of all the electric appliances, their power requirements and how long they are used daily.

For instance, someone uses two lights consuming 1 amp power each for 3 hours, the power consumption will be 2×3= 6 ampere hours. If all appliances need 20 ampere hours each day and the capacity of the battery is 120 ampere hours, it will last three days without recharging and if it is AGM battery, it may last a little longer.

Taking another example, suppose someone has two 100 ampere hour AGM batteries connected in parallel, with at least 50% or 100 ampere hours in reserve, the battery charge is likely to last for three days without any difficulty even if he uses several household equipment, such as water pump, TV etc.

However, it is better if he uses a battery voltage monitor to check the level of charge from time to time. A good battery charger is as important as a quality deep cycle battery. Among several types of battery chargers, a ‘smart multi-stage’ battery charger is a top-rated battery charger that will charge the battery quickly and also attains high level of charge.

Besides ensuring a longer lifespan for the battery with more capacity than when charged using a constant voltage charger costing around $20. Where batteries are to be placed depends on their type. When connecting two batteries together, it is important to make sure that the correct size of cable is used.

If the cable is not of correct size, the batteries will not work. It should be noted that if the wire is of smaller gauge, there will be more voltage loss and a longer run will also cause more voltage loss. In case of any doubt, the user should get professional advice in these matters.

A Do It Yourself (DIY) electric car is a vehicle which needs to be maintained for their long service life. On this basis, the consideration on preventive maintenance of the batteries is essential on the value that is to be retrieved out of the amount spends for your EV.

Job maintenance for an electric car doesn’t end in just checking up the wheels and cleaning it. Since it is and electric vehicle, the importance of the battery determines the proper functioning of the electric motor.

There are three basic needs that are to be considered by the driver, they are, the trust upon the brand, reasonable rate and clear specification of the battery. In deciding a brand there is a must to consider on the suitable location, because there are certain brands which work good during cold season, and simultaneously there are other brands which work efficiently during the hot seasons too.

Interstate Batteries and Trojan are in the top list in selling high quality batteries and as per the name, the batteries also perform very well in all condition. When there is a comparison between the batteries of Exide against these two names, it is noted clearly that life span of the battery is less in Exide, all though the price is lower.

In buying a suitable battery for your electric car, there is also a decision to be considered, that is “price factor”. The minimum price for buying a deep cycle battery is $75. But you should remember on the price of the product, moreover which are technical in nature, relates to the reasonable price.

This is price range for the batteries, which are offered by the local brands, but they don’t work for the long run. The price range also fluctuates on the basis of the size of the electric motor. For heavy EV, the price range of a battery goes on to $300 to $400, and the buyer should also be aware of the warranty of the battery.

The other specification to be considered is the size of the battery, the working hours of the electric car and the loads added on the vehicle. Before purchasing the battery, you should know on the size of the battery that will fit in to the car easily.

If the working hours of the EV are high and heavily loaded, then you should decide upon purchasing a high power battery. When you bought an electric car conversion kit, there will be a manual attachment which gives all the information about the battery maintenance. So the first thing to consider is to read the manual on basis of do’s and don’ts with regard to battery.

The driver must also inspect weekly or monthly basis, whether the battery has some leakages, any loose connections or any damages. If any damage is found on the battery, there is no need to use it anymore. Even if it is still in working condition, replace it immediate because it will affect the performance of the entire battery bank.

Cleaning the terminals, body and metal ports are the maintenance job for a homemade electric vehicle. While cleaning, all the connections should be detached. The cleaner should be aware in not wearing any ornaments.

Proper charging of a battery determines good health of a battery. Excess charging of the battery affects its lifespan. In order to stop the charger at the required time, automatic timers and LED indicators are attached. These are the right basic tips on maintaining the right battery for an electric car.

Will you have a hybrid of gas and electric or a complete electric car? A hybrid car has an electric battery and a gas engine that works together to power the car. While the hybrid can drive for short distances using just battery power, it’s not good for touring.

A fully electric car makes it difficult to drive much longer distances as you will need to eventually recharge. For trips around town, it is doable.

To create such a car, you can try using solar power. What happens when it is cloudy? Although it isn’t completely off the grid, you can plug your car’s battery to recharge the solar cells.

Plugging your car into any outlet won’t work as the car will need much more power. A standard household socket can charge the car but it will take longer. You will need a dedicated charger.

Advances in battery technology makes lithium batteries most suitable for electric cars. It holds a charge much longer and is better for driving longer distances.

To store energy in lithium batteries, using wind or solar power can charge them while being completely off the grid. When charging is complete you can drop the battery into the car and drive wherever you need to go. It is a great option for backup batteries that you can store for later use.

You can use solar, deep cycle, airplane, and golf cart batteries. Golf cart batteries are the best and cheapest to use. To determine how many batteries you need, you need to figure if you are using DC or AC conversion.

Using lithium batteries have no need for DC/AC conversion. Lithium batteries aren’t cheap, but it lasts the longest.

To make an electric car, you will need a donor car (preferably a newer model as parts are hard to come by for older cars) with lots of room for battery cells. Depending on the battery you use will determine how fast the car will go, how much electricity it can contain, and how big of a space you need to build the engine.

The car must have a manual transmission for the conversion to work. Having a car that is light in frame is best.

Purchase a conversion kit.

An EV conversion kit has everything you need and the costs are reasonable according to what size and actual parts you need. In spite of the fact that you can use surplus parts, it’s best to buy something already readymade. When acquiring parts, remember, buy from reputable dealers. You just don’t want any old part to put into the car.

You will also need some mechanical know-how as converting a gasoline powered car to electric is quite a task. The transmission adaptor plate and assembly that fits the motor is quite precise. If you don’t know what you’re doing, take your project to someone who does, but with a conversion kit and following instructions you can do the retrofitting yourself.

With the advanced technology all your worries about the rising prices of gas are over. Though this is not something new, electric cars have been there for the last almost more than two decades. There are slight changes in these cars as compared to traditional cars; the inner works have a rechargeable battery pack that provides power to the motor in order to move on.

But apart from electric cars there are cars which have both electric engine and the conventional standard combustion engine, such cars have been named as hybrid cars. An electric car runs only on rechargeable battery pack and the electric battery provides the necessary energy to the electric motor and the car starts moving.

Since the car runs on electricity there is no carbon emission and this makes such cars as non-pollutant car. These cars are highly approved by the environmentalist and the car is known as green car.

These cars have very simple motors which are powered by several powerful batteries which has a standard off and on switches. The switch is attached to motor which also runs on the electric power. The electric motor gives motion to the wheels which enables it to move forward or backward.

The amount of electricity required for the motor and the gear system can be regulated, this enables driver to have more control on the wheels. There are some cars which run on solar energy and are fitted with solar panels; these panels convert the Sunlight into the energy which provides necessary power to run the car.

Electric cars are very easy to operate and can accelerate very fast due to low center of the gravity. Even at the slow speed, the electric car maintains its momentum, so can enjoy your drive and can also take sharp curves. There are many things in electric cars to make it more attractive for the car users who are sick of rising gas prices and want to get rid of the traditional cars.

All those features which are available in the cars which have combustion engine can be found in the electric cars also, the only one thing changes is the source of power, rest all is same. Now you have car which does not run on fuel but on clean energy that is electricity.

You can convert your existing car into an electric car without having to purchase a complete new electric car. This exercise will save you a lot of money; this needs some technical knowledge and a good DIY electric car conversion guide. Such guide provides you step by step guidance in converting you existing gas car into an electric car.

In view of this alarming scenario, owners of cars have been seriously looking around for other types of cars that give the same mileage as gasoline-powered cars that consume a lot of fuel and cars whose maintenance costs are also comparatively lower.

Electric cars, also known as electric vehicles or EVs, are excellent alternatives to traditional ‘gas-guzzlers’. Ever since its invention, the electric cars have been competing with traditional vehicles.

However, the demand for EVs dropped ever since Ford began manufacturing its ‘Model T’ cars on a large-scale and soon electric cars went off the roads. Since that time, car manufacturers have been hesitant to manufacture electric cars except for displaying in showrooms. This situation continued till 1996 when General Motors manufactured numerous types of electric cars such as EV1.

However, the reentry of electric vehicles received a lukewarm response and was a failure mainly due to oil companies and a few major car manufacturers, who thwarted every attempt of EV’s to come back into the automobile markets.

As the name implies, electric cars are powered by electricity. They were first launched in 1880s and were very popular during that time primarily because of almost noise-free engines in comparison with the disagreeable noise produced by internal combustion engines of gasoline-run vehicles.

In addition, the maintenance costs of electric cars were comparatively low. However, in view of several factors, electric cars could not compete with traditional cars and were soon out of the market. Nevertheless, the demand for electric vehicles revived once again not only due to cost factors but also because they are pollution-free Eco-friendly cars.

As electric cars do not utilize any fossil fuel and other similar natural resources, they do not emit any harmful gases. That is the reason why electric cars are popularly known as “ZEVs” or zero emission vehicles.

Electric cars have also become very popular once again because the present day traditional gasoline-run cars are considered responsible for emission of greenhouse gases causing global warming due to air pollution. With the rapid development of technologies in the automobile industry, the components of electric cars have substantially come down.

These innovations have also contributed to the production of more sturdy and efficient electric cars. Electric car batteries available these days have much longer lifespan and can cover more mileage per charge than before. All the other components are easily available in most of the departmental stores and hardware stores.

There is an increasing awareness among a number of car owners these days about the numerous advantages of using electric cars. As many car manufacturers do not make electric cars, several people have started constructing an electric car as Do It Yourself (DIY) job.

Anybody can have a homemade electric car with the help of instruction manuals. Many people convert their cars into an electric vehicle on their own as a hobby and this has become a fascination for some people. The concept of converting their cars into electric cars is catching up fast.

One can get the details of various components required for building an electric car and the places where they are available at reasonable prices. Apart from this, they are a lot of ‘online forums’ where people interested in electric cars can share their ideas and extend all assistance to those who want to construct an electric car.

Many people are also trying to create awareness among car owners encouraging them to convert their cars into electric vehicles. However, unless more and more people come forward and appreciate the importance of electric cars, the demand for these types of cars will not pick up much and traditional cars will continue to be manufactured on a large scale.

When you combine water and iron (including steel) you get rust. Rust is a result of reaction between water and iron in the presence of oxygen. The more rust there is the faster it will keep rusting.

Given enough time, rust will destroy anything made of iron. Once rusting starts, it is difficult to stop. The best way to protect iron products is by coating them properly. Once rusting begins the only way to stop it is to completely clean the rust away.

What exactly is rust? Rust is hydrated iron oxide. Oxygen, water and iron react to form this compound. It first appears as brownish coating over the surface of iron products.

Rust will bubble paint or other coatings off the iron or steel. Rust also leaves ugly stains on any surfaces in contact with the iron. It will also destroy the iron making it weak and fragile. Can you see how bad rust could be on your DIY electric car?

Any item made of iron is susceptible to rust. The best way to deal with rust is to prevent it from rusting in the first place. Once metal products start to rust, it will not stop until the entire part is destroyed. Therefore you need to watch carefully for telltale signs of the initial stages of rust. Once rusting starts, you must treat it immediately or it will spread like cancer to other metal parts of your vehicle.

How can you prevent rusting on your EV project donor car? Firstly, you have to keep oxygen and moisture away from any iron products on your car. Since an automobile is made mainly or steel, doing so will be a tall task. Remember, iron rusts when it comes into contact with water and air. So, when you take either water or oxygen, there is no rust.

Now, moisture and oxygen are everywhere; so how can we stop them from coming into contact with the metal? The most common solution is by coating the surface of the metal with a material that will not allow moisture, water and oxygen to penetrate in.

As we all know that oil and water repel each other, therefore grease and oil can be a good insulating material for metals. If you apply oil, grease, primer, paint or any other oil-based coating all over the metal surfaces it will prevent rusting.

However, the problem begins when the paint coating comes off either from wear and tear or from scratches. To prevent the occurrence of metal oxidization, even the smallest scratch should be resealed as soon as possible.

How to choose an anti-rust solution for your homemade electric car? The way you select the right option is by determining where the coating is to be used.

Since the donor car you used for your DIY electric car project is old, chances are there will be some levels of rusting. Begin your restoration work by cleaning the rust off any metal surface.

To make your work easier, use a spray on rust remover. With a spray product, your work is reduced to just spraying and wiping. Using sandpaper and other products work but are very labor intensive.

With organic rust removers, you can get rid of rust without any mechanical work. On severely rusted parts, you may have to repair the metal before re-coating it. No doubt it is a lot of work, but trust me, it is all worth it. After you’ve spent thought thousands of dollars and months on converting your conventional automobile into a pure electric car, you don’t want your EV to fall apart due to rusts on the metal components.

Purchasing a new deep cycle battery can be costly. Cells from such a battery, running at approximately 2 volts, can run you from $300 to $600 – quite a steep price, considering even a small, 12 – volt setup, running 650 Ah, would cost around $1,800!

Perhaps you merely need a replacement; perhaps you’re trying your hand at desulfating and reselling deep cycle batteries. A large, used deep cycle battery can easily be broken down into its still-functional cells and incorporated into an eco-friendly, home renewable energy system, which would require anywhere from 12 to 48 volts.

Or perhaps you’re looking to replace a dead battery, thus a battery from a golf cart might serve just as well at powering a DIY electric car, for reasonably cheap (only $80) and provide 220 Ah, but for a only quarter of the time.

You can save a substantial amount of money from restoring old batteries because a refurbished battery can be sold for $100 each, and last double the time – or more – than the smaller, golf cart batteries.

The first set of old deep cycle batteries I personally refurbished were for free, disposed or recycled from a business. In breaking them down, I realized the majority of cells in any given recycled battery are still operational; typically, only a small handful of cells no longer work (in my case, only three).

At 24 volt, 700 Ah, with 12 cells in each, I recovered twenty-one still-functional cells. If I chose to sell them (rather than keep them, as I did), I could have profited up to $2,100: a healthy margin for a recycled battery! But bear in mind, despite all your best efforts, a battery will never return to its original capacity.

By removing the bad cells, however, up to a vigorous 90% might be recovered. Always remember to recycle those cells that are no longer useful to you. It’s easy to locate deep cycle batteries to begin refurbishing.

Get in touch with local business that may be able to provide you with free, recycled batteries. Warehouses or recycling depots would be a good start.

It’s best if you offer to pick up the batteries yourself, and you may be required to sign a waiver or other paperwork, for environmental factors, but for the most part, such companies are grateful not to have to dispose of the batteries themselves. Such old, exhausted batteries are almost always simply taking up space!

Deep cell batteries are rather large, and quite heavy (a 24-volt battery can weigh up to a thousand pounds), but with a truck they can generally be transported; anything larger than a 24-volt deep cell will require careful preplanning.

Be sure to have arranged your transportation well in advance. Alternatively, you can always inquire at any golf cart service garage in your area, as they will often offer stock for sale and may even deliver, but this will likely cost you a fee – usually only a few cents per pound.

At such a low rate, delivery is certainly an option. But, even if you chose to take the delivery route, if you have the skill and time, refurbishing a deep cycle battery is well worth it, whether you’re recycling for your own benefit or for profit.

Electric Golf Cart Battery Reconditioning

If you are thinking of refurbishing old electric golf cart batteries and bring them back to live, check out the Electric Golf Cart Battery Guide at www.golfcartbatteryguide.info/ for easy tips and suggestion.

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