It is best to select a small car as the 'donor' car,
preferably a hatch type so that access to the rear for the batteries is
easy. Choosing a small car allows you to take advantage of the low
weight of the car. This will make the motor and battery choice easier
and cheaper as well. The more weight in the car means bigger motor and
bigger (higher capacity) batteries.
When choosing the car, select one which has a good
body, gearbox (transaxle), suspension and brakes.
The state of the Internal Combustion Engine
(ICE) is not important of course.
Choosing a good body means that you
don't have to spend valuable time fixing rust holes, panel beating and
It is a good idea to start with a manual gearbox car.
It is possible to convert an automatic drive car but there are great
power losses in the transmission and the auto transmission is not suited
to the high rev range of the electric motor - not recommended.
Some suggested cars are:
||Suzuki Swift * (This website)
example (2nd car in video)
||Holden Barina * (This website)
* The original Holden Barina was produced by Suzuki
Note: For second hand cars, it is good to look at
those from the 1980's and early 1990's as these don't normally have
power steering. If it has power steering this adds more complexity and
another electric pump (more power drain).
It is good if the donor car has power brakes so that it can easily
handle the increased weight of the converted car.
The car that I have selected is a Holden Barina MB (rebadged Suzuki
Swift) 1985 model with only 155,000Km on the clock. This car has a good
body with no rust and good suspension. I had the car checked
by GMR Motors and it only required new brake cylinders on the rear
wheels and a boot on a CV joint.
The Holden Barina 1985 has an Kerb Weight of 710Kg
(from the specifications) and a
Gross Vehicle Mass
* (GVM) of 1260Kg.
On the weighbridge the front measurement was 450Kg (62.5%) and the rear was
270Kg (37.5%) before I started the project.
Note: I am removing the back seat and as such converting the car into a
two-seater. This effectively saves 3 x 81.6Kg (244.8Kg) in the final GVM by removing
3 passengers. The GVM includes all passengers and driver at a rate of
81.6Kg per person including luggage and a petrol tank 75% full !
I will be placing the batteries where the back seat was, hence the
weight of the batteries will be divided up between the front and rear
axles. I will have no extra weight in front of the front axle or behind
the rear axle.
I am predicting that the final curb
weight will be under 800Kg.
It is the GVM that
should not be exceeded - keep this in mind if using (very heavy) lead
acid batteries (eg. over 30Kg each and for 120V you need 10 ! )
A very good web site for finding out about a car's specifications is:
To print results select "Printable View" button, while at this