WHO I AM
I joined the Australian Electric Vehicle Association in Sydney and am currently building a third prototype of my conversion car. I spent years juggling this project. I remember my first club visit, most of the key members were there. They are still part of the club. Over the the years, they helped me design and build. But, it was not always fun. Staying committed was challenging, and I faced numerous failures. Despite the challenges and the lengthy process, this journey has taught me resilience and the importance of community. Each step, no matter how small, has pushed me forward. Now I am proud of what this car has become, and I look forward to the next chapter, and I am still curious about what the next release will look like. How to squeeze all juice out my battery is the my first mission, alongside some cosmetic improvements, paint detailing, a radio retrofitted with "cassette", and more fun stuff.
Model 1 - Completed in 2019 (Failed roadworthy registration)
Model 2 - Completed in 2023 (Passed test and registered)
Model 3 - Work in progress. Next release expected around 2028
CONVERSION SUMMARY
I’ve removed the V6 engine along with the automatic gearbox and replaced them with a manual 5-speed gearbox from a Mazda 3. It involved carefully mounting the new electric motor onto the gearbox using an aluminum conversion plate while keeping the clutch intact, and I also installed a custom-made high-voltage battery. It sounds straightforward when condensed into a single sentence! Once the wheels were turning, there were a few additional components that needed to be installed to ensure everything was ready. This is a fantastic ongoing project for me—more of a learning experience than anything else up to this point. The test drives have been a joy; the design looks promising, and the build quality is quite reasonable. My goal is to build my model 3, a safe vehicle that can carry my family and me for short trips of up to 70-100 kilometers on a single charge. The current model 2 has a range limitation of 52 kilometers and the charging is extremely slow.
I hope you enjoy reading about this journey!
Model 3 and beyond
I truly hope to enjoy this car for at least another 15 to 20 years. Although it is intended for short-range operation and generally has a slower driving speed, the overall driving experience and the enjoyment of manual gear shifting make this car perfectly okay with me. I've been asked many times whether starting a project like this is worth it, what the value is, what the enjoyment factor is, and why I choose to mostly use recycled materials instead of purchasing new parts. People also wonder if I would recommend it and whether I can provide an estimate of the conversion cost and the cost of ownership. I do recommend it, and I would do it again. No matter if you are tight in budget, there is much to gain.
Example Lesson Learned:
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Purchasing a relatively expensive AC motor was a good decision, but buying it without a warranty was a mistake.
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The original car had an automatic gearbox, which led to significant extra work, such as the ODO and speedometer ceasing to function. Next time, I will start with a lighter car featuring a manual gearbox, which will be easier to convert.
HELLO,
MY NAME
IS STEPHAN
FOLLOW US
I’M ALWAYS HAPPY
TO GET TO KNOW MY READERS AND SHARE INSIGHTS AND IDEAS.