Educational Institutions Begin to Fill the EV Technician Labor Gap
Photos by Legacy EV
Wow, we have all heard the stereotypes about the kind of people who go into careers in automotive service and repair, right? It is a frustrating misconception that working with our hands is somehow not a worthy career. But even with the EV industry predicting that it will create 200,000 jobs in the US by 2030 and a growing number of EVs on the road, high-paying, high-quality careers as EV technicians are sitting vacant.
So, how can we best prepare for the hockey stick-shaped growth curve of the EV industry and the jobs needed to support it?
This hands-on training goes a long way in preparing learners for successful careers in the dynamic field of e-Mobility.
It has been described as hockey stick-shape because excitement and press around the addition of alternative fuel to the auto industry has blown up, but funding and actually putting pens to paper is a slow process. An entire year has passed since our federal government started investing in EV workforce development, infrastructure, and manufacturing, but seeing that trickle down into your town takes time. However, there are a few local governments and colleges that were early e-Mobility adopters and will springboard a cultural shift in the importance of careers in the automotive industry.
Up-Skill and Invest!
And what are the two core workforce investments needed for this shift? Up-skilling your existing automotive workforce and investing in a new generation of gearheads. Think about it! Middle school robotics programs are really just creating gearheads for circuits, basic high school coding classes set you up to play with a dyno, and social media product reviewers now consider EVs another piece of tech. We are inspiring the next generation to get back to problem solving, rebuild that tech trash and make it battle, and fix up your ride to show off to others (and post for likes).
It is high time we start realizing the potential of hands-on skills, including the value of careers that just can’t be replaced by automation.
Manufacturers and colleges are contributing to this subtle shift. Rivian, for example, has partnered with Illinois Governor JB Pritzker to build a $7.5 million dollar Electric Vehicle-Energy Storage Manufacturing Training Academy at Heartland College in a small town called Normal. Students can earn an Associates of Applied Science degree and qualify for an interview for one of Rivian’s 4,000 jobs needed in its new nearby facility.
States like California are going even further to refrain from lumping it into an EV-only category and are instead offering “alternative fuel” courses. At Saddleback College in Mission Viejo, students can become Alternative Fuel Specialists, gaining knowledge from Legacy EV training benches to learn the fundamentals of hybrid, EV, and emerging alternative fuels. Raj Dhillon, senior lab technician at Saddleback College, remarks on his school’s use of an EV training bench for hands-on learning in the classroom.
“It offers a comprehensive, product-agnostic learning experience, perfectly suited for [those] seeking to instill in their students a solid understanding of EV fundamentals,” he says. “This hands-on training goes a long way in preparing learners for successful careers in the dynamic field of e-Mobility.”
Then, right outside of Motor City, Ontario, Canada ranks number two in vehicle production behind Michigan and has built entire EV programming for their automotive students. At St. Clair College in Windsor, Ontario, students can earn an industry credential as an Electric Drive Technician, and then go on to complete an apprenticeship in the field or continue their education to earn an EV Technician degree.
All Hands In
As these high-need positions sit vacant, colleges and manufacturers have put considerable investments into promoting these valuable careers and supporting training for diverse individuals, like Justice40 communities and women. In fact, according to MarketSource, only 1.5% of the technicians currently employed are women—no doubt caused by the cultural stereotype around auto techs and working with your hands. It is high time we start realizing the potential of hands-on skills, including the value of careers that just can’t be replaced by automation.
Is your school supporting hands-on innovation and problem solving? Is your town investing in e-Mobility workforce pipelines? We’d love to hear from you! Tell us your story for a chance to be featured in EV Builder’s Guide.
Classic Revival: The Electrifying Journey of a 1993 Defender
The Daring Electric Conversion of a British Classic
Photos by Jerome Andre
In the sun-dappled Bristol, UK, development workshop, a superb 1993 Arrow Red and Santorini Black Defender sits quietly. This isn’t a preamble to another of its rugged adventures over rocky terrains; instead, we are here to discover its journey into an utterly new frontier—electrification.
To the Land Rover purists and adventurers, the Defender’s hearty diesel grunt or the V-8’s rumble is music to the ears. But let’s imagine it combining forces with the silent power of electric drive synonymous with unbridled exploration across both serene and unforgiving landscapes.
In a world where progress often comes at the cost of nostalgia, a novel electric conversion system juxtaposes the cherished classic Defender with cutting-edge electric technology, heralding an unexpected alliance. Electrification, particularly within the sacred halls of classic motoring, might initially ruffle a few feathers, and the concept of transplanting a serene, electric powertrain into the brawny, mud-slinging Defender could well be perceived as downright iconoclastic to the devout aficionados.
But delve a smidge deeper, beyond the potential sacrilege, and the notion of an electric Defender tantalizingly begins to unfurl its appeal. Imagine, if you will, the silent torque surging, empowering it to glide over hills and obstacles with newfound grace, all whilst eschewing the traditional mechanical cacophony.
Enter the team at Fellten (meaning Lightning in Welsh), composed of brilliant minds and impressive craftsmen. Based in Bristol, the company has made a name for itself around the world by designing and producing conversion systems for the industry and Hollywood studios – and now, they’ve set their sights on the mighty Landy.
At its core, Fellten designs, engineers, manufactures, and distributes OEM and aftermarket battery packs, electric motors, and complete bolt-in, plug-in conversion systems for Porsches and Classic Minis (approved by MINI). Its footprint spans the UK, Australia, North America, and Europe, where its commitment to excellence shines through as it sets industry standards for quality, safety, reliability, and production volume. The company’s upcoming South Gloucestershire production facility is poised to deliver hundreds of battery packs per year to OEMs and conversion systems to its approved international network of conversion specialists.
Beneath the Hood: A Silent Revolution
Fellten’s system consists of the amalgamation of a new Tesla Model 3 rear drive unit and Fellten’s universal battery pack, flaunting an astonishing 55kWh capacity. The ‘UBP55E’ has been developed to fit most engine bays originally fitted with a straight-6, V-6, or V-8, but the requirement was also that it fits any Defender. This pack is available from Legacy EV individually or as a conversion systems bundle.
The Model 3 powerhouse replaces the whole internal combustion drivetrain: a 2.5L 200 TDI block, gearbox, and transfer case. This is ultimately a better engineering system than coupling a compact electric motor to the original transmission, not least because it’s a great deal more compact. That’s important when one of the goals has been to maintain the original Defender’s overall mass and its weight balance, so inherent in the character of how it handles off-road or towing. The Tesla drive unit, position lengthwise, sits dead in the middle of the length of the 90, where the G- and T-box combo was: There is no need for a transfer case since the mighty motor delivers 100% of its torque from standstill to max speed!
The battery offers a formidable peak discharge of 330kW along with an industry-first CCS rapid charging at a rate of 70kW. This means you can top up your battery from 20 to 80% at any rapid charger in around 35 minutes. Last, its IP67 protection safeguards its intricate technology from the British weather’s repertoire, from drizzles to downpours, whilst offering a low and steady center of gravity to the 90.
Just like other EVs, when you drive the Fellten Electric Defender, you always leave home or your workplace with a full “tank.” This means you typically only need to charge during longer trips. For daily sub-200 miles commutes, simply plug it in every night, much like you would with your mobile phone and leave the next day fully charged.
Designed with both pragmatism and finesse, this fully weatherproof “universal” battery pack enthralls with its discreet but robust capabilities, encapsulating battery management, high-voltage pre-charge circuit, contactor control, and more, all within an astoundingly compact space. All the technology is well-protected, and there are no wires, cables or piping sticking out of its steel and carbon-fiber shell.
Extra Pack
According to Chris Hazell, CEO of Fellten, the easiest part of the build was scanning the engine compartment and components to create the 3D space for designing. However, engineers encountered several challenges, including the packaging constraints to fit the main battery box and ensuring that no modifications were made to the vehicle to stay within the regulation’s requirements.
Since there are no shortcuts in building an EV conversion system that is unobtrusive and designed to OE-level specifications, the Fellten team solved these challenges using CAD to design and create a secondary 55kWh battery pack that replaces the whole seat box. Like the rest of the system, both battery packs come with a three-year warranty
Crucially, the whole back of the 90 is unaltered by the conversion, meaning 100% of the back remains stock and can still receive all the goods one needs to carry or seats with passengers. Towing capacity is also similar to the original, though depending on load, the power usage will rise, just like fuel consumption rises on a diesel or V-8 Defender.
A Defender purring quietly with the might of electric power does more than just preserve a classic; it propels it into the future.
Unmatched Warranty
Fellten, and the US’s market leader in aftermarket EV applications, Legacy EV, recently announced a groundbreaking partnership, marking a new era for the e-conversion industry in the United States. Leveraging Fellten’s advanced conversion solutions and Legacy EV’s leading position in US-wide distribution and dedicated training, the partnership is poised to bridge the past’s automotive legacy with the future of electric propulsion. Legacy EV will serve as the exclusive distributor for Fellten’s state-of-the-art components, e-motors, battery packs, and its complete bolt-on, plug-in conversion systems throughout the USA. The deal also encompasses coverage for Fellten’s unique three-year warranty. To ensure optimal product utilization and consumer satisfaction, Legacy EV will harness its vast network, providing rigorous training for technicians across all 50 states.
LEGACY
When engineering this particular 90, the team opted for a brand-new galvanized chassis, which was not a requirement. In fact, several specialists in the UK and worldwide opted to focus solely on the system installation as long as the base vehicles are sound with a solid chassis. Some of them even perform the conversion in just one week, followed by a full week of testing.
Specialists already offer this conversion system with more joining the ranks upon following Fellten’s dedicated High Voltage virtual and in-person training at their training studio.
To meet strict government bodies’ requirements around the globe, there are no required modifications to be made to the body or the chassis – not even a single hole that needs to be drilled.. That’s good for purists of originality, of course, but more importantly, it means there’s nothing you couldn’t return to standard here or update and evolve in a few years.
Driving: The Symbiosis of Old and New
Upon ignition, the electric Defender offers an experience that is uncannily serene yet familiar. The absence of the traditional 200 TDI growl is filled with a gentle electronic hum, and as the vehicle eases into motion, it reveals a driving experience that is both novel and comfortably recognizable. Its regenerative braking system mirrors the engine braking of its diesel predecessor, and one-pedal driving becomes second nature swiftly, marrying the ease of electric driving with the traditional, robust Defender character.The Defender easily reaches 90 mph and a 0-60 time of 6.5 seconds. Compared to a diesel-sipping 200 TDI, the equivalent performance feels absolutely effortless, thanks to the electric motor’s instantaneous at 300lb-ft, upgradable to 600Nm (442lb-ft) and currently at 150hp -that could be pushed up to 220kW (300hp).
One-Pedal Driving
The 90’s regenerative braking system operates impressively, mimicking the engine braking encountered in a diesel Defender on a low gear. It becomes intuitively easy to adapt to within a brief moment. It becomes quickly apparent that the primary use of the right pedal suffices, reserving the actual brake for emergencies or halting at traffic signals. Engaging the go pedal absolutely outpaces a new supercharged V-8 Defender!
To commence the drive, activate the ignition key and choose D on the panel located on the dashboard. From there, operate it like any other EV – or an automatic Defender. Rest assured, the distinctive character of the Defender, complete with its iconic sounds, vibrations, and rattles, remains intact.
Now, the elephant in the room is that you lose the 200 TDI sound. True, but that’s about the only trade-off. Then again, ‘filling up’ the electric Defender 90 cost less than a pit stop at…Starbucks!
The Defender, often likened to a mobile brick, does not offer the range at higher speeds that one might experience with the aerodynamically sleek Tesla Model 3. When traveling above 50mph, the majority of the energy is consumed in navigating air around the Defender’s front. Nonetheless, the vehicle’s shape less significantly impacts the range in urban settings, on the farm, or within woodland areas.
A global consumption estimate for the electron-fed Defender hovers around 500W per mile in practical use. This is double the energy usage of the latest premium compact EVs – mirroring how a traditional internal combustion engine Defender demands twice the fuel of a smaller, lighter vehicle.
Conceivably, gentle cruising without aggressive acceleration can achieve better than 500W/mile, though, during our trial, such restraint was challenging due to our allure while overtaking any vehicle slower than a sporty hatchback or trying to find the BF Goodrich Trail-Terrain T/A’s traction limits. These have been brilliant in the rough stuff, by the way.
In rugged terrains, the Fellten 90 introduces another advantage. The engineers have crafted modes, akin to the Terrain Response, including a specialized Crawl mode. Once activated, the accelerator pedal’s response adjusts, providing more nuanced control and gradually permitting additional torque for climbing over rocks and obstacles. This feature proved beneficial during the 90’s testing through a muddy, narrow path and a wet, sloping, grassy track.
Made for the Trade
As businesses ponder the viability of electric conversions, the Fellten system unfolds as an enticing prospect, providing a potent yet user-friendly technology. As stated by Chris, the FL10 UBP55E was developed to facilitate businesses in seamlessly adding electric conversions to their portfolios without entanglement in complex installation processes. Beyond the technological offering, Fellten extends its hands in training and comprehensive support, paving a pathway for the classics to glide into the electric future, equipped and empowered.
Financial Prudence in the Electric Pivot
Embracing this electric renaissance requires a $62.000 investment (retail price, fully installed and tested). Yet, this financial commitment is not merely an ecological statement but a savvy, long-term economic strategy, particularly compelling for those navigating through the stringent emissions norms of urban environments. The electric Defender promises substantially lower running costs at a mere $5.50 to charge from 0 to100% whencompared to $36 to travel the same distance in a diesel 90. That is an 85% savings.
Moreover, the elimination of numerous mechanical components significantly reduces maintenance costs, rendering the upfront investment astute, especially in an era gradually gravitating towards zero-emission mandates. Also, the conversion-to-electric industry is anticipating there could be incentives for converting an internal combustion engine sooner than later, as it is already the case in some countries around the globe.
Last, 60 grand plus a donor Defender is still significantly less than what Land Rover will charge when they eventually offer the current generation ‘L663’ Defender in a full-electric configuration. More importantly, retrofitting lets you keep your own iconic and beloved classic Defender. The only major drawback is you will have to do without your Landy for two weeks while Fellten-certified installers work their magic.
A Quiet Odyssey into Tomorrow
This electric Defender doesn’t simply traverse the landscapes; it traverses eras, embodying an amalgamation of cherished heritage and forward-thinking innovation. It invites us to ponder, to explore, and ultimately accept that the future of classic motoring can, indeed, be electrifyingly bright. A Defender purring quietly with the might of electric power does more than just preserve a classic; it propels it into the future, creating a beguiling blend of the historic and the modern in a package that’s ever-so-tantalizingly British.
SPECS
Electric 1993 Defender 90 hardtop (originally a 2.5L 200 TDI)
Conversion: Fellten (production will be performed by a network of specialists)
Time to build: Installation by approved specialists will be five daysMotor Drive: Tesla Model 3 rear drive unit
Power: Up to 220kW (300hp) – currently at 150hp
Torque: Up to 600Nm (442lb-ft) – currently at 400Nm (300lb-ft)
Motor mounts: Custom onto original Land Rover mounts
In the world of custom car enthusiasts, few stories capture the spirit of innovation and personal expression as vividly as that of Bucky Howard and his Tesla Model 3, affectionately named OUTAGAZ. Featured over a year ago in EV Builder’s Guide, Bucky’s journey from a gas-guzzling past to an electric, Technicolor future is not just about modifying a car; it’s about redefining how cool an electric vehicle can be.
Bucky’s story is steeped in the neon-lit backdrop of Las Vegas. His upbringing, influenced by his father’s renowned status in the gaming industry and his mother’s artistic prowess as a professional dancer, shaped his unique perspective on life and automobiles. This blend of spectacle and creativity is vividly reflected in every facet of his Model 3, turning the car into a mobile canvas that mirrors the vibrancy of Vegas.
Bucky’s automotive passion was ignited in the world of custom mini-trucks, celebrated for their low-to-ground stances and mad styles. His first automotive fascination, a Chevy S10, laid the foundation for his lifelong devotion to vehicle customization, but Tesla’s entry into the automotive market marked a pivotal shift in Bucky’s focus, leading him from traditional gas engines to the innovative domain of electric vehicles.
The Genesis
Purchased in early 2020, Bucky’s Tesla Model 3 SR+ quickly transcended its original form. This transformation was more than a routine upgrade; it was a bold statement against the misconception that electric vehicles were not amenable to personalization.
“There’s a prevailing notion that you can’t customize an EV,” Bucky remarks. “But my Tesla stands as a testament to the contrary.”
OUTAGAZ is not just a vehicle; it’s a convergence of meticulously chosen modifications. The suspension, masterfully crafted by MadHouse Customs and The Fab Lab, includes a Universal Air Suspension solution series and Airlift Performance 3 PM Management system, establishing a stance that is as functional as it is aesthetically striking.
OUTAGAZ’s exterior is a canvas where Bucky’s creative vision is vividly expressed. Wrapped in a limited edition Inozetek Anti Social Social Club color “Spectrum,” the Tesla’s appearance morphs with each shift in light and perspective, akin to the ever-changing Las Vegas skyline.
‘‘The film was then wrapped in Stek PPF paint protection film, and then ceramic coated over it,” Bucky says. “It just makes it look like paint when you stare at it. Every show it goes to, I get lots of reactions. I love it when people say they love the paintjob—but it’s not paint!
“The best part is if something gets scratched, I have a couple spare rolls that we can use to fix that one panel versus try and paint the whole car,” he continues, “so it has its benefits. Sometimes I wish I would’ve painted it because it turned out to be about the same price. But no going back, because now I’m all in. And depending on how the sun hits the car, it really brings many different colors. It’s my personality. I’m loud, just like my car is.”
That is an understatement, as you can see yourself on his channel: YouTube.com/Shottytv
Additions like the CMST double-sided gloss carbon fiber hood enhance its sleek, modern look. One of the most striking features of OUTAGAZ is its lighting. The Teslux Innovations RGB headlights and LED sequential fog lights from Hansshow not only enhance visibility but also add a dramatic flair to the car’s front end. The stock taillights, wrapped with Inozetek, maintain the Tesla’s original design while blending seamlessly with the car’s new color theme, being partly wrapped. The rear bumper is adorned with LED sequential lights from Hansshow, completing futuristic look. Adding to the car’s style, the frunk features RGB lighting from EV Base, just like the automatic RGB door handles by Hansshow.
Interior: A Fusion of Tech and Artistry
The interior of OUTAGAZ is a testament to Bucky’s commitment to excellence and his eye for detail. MadHouse Customs, the shop responsible for the interior overhaul, ensured that every element resonated with the car’s overall theme. The interior is a lavish display of carbon fiber, covered with the limited edition Inozetek color. The seats, white with a protective ceramic coating, provide a stark contrast to the vibrant colors of the car’s exterior. The steering wheel has left in favor of a carbon fiber yoke wrapped in white leather and Inozetek vinyl. Adding to the auditory experience, two Kicker 12-inch Solo Baricks subwoofers with RGB speaker covers are painted white, with the box covered in the same carpet color as the stock Tesla carpet. These are powered by a 1200-watt Kicker amp, cleverly hidden in the sub-trunk compartment.
I love when people say they love the paintjob—but it’s not paint!
The door panels, featuring a carbon fiber overlay from RPM, are wrapped in the limited edition Inozetek spectrum color, echoing the car’s external finish. The full carbon fiber seat backs, also from RPM Tesla, are similarly wrapped, creating a cohesive look throughout the vehicle. The dash, originally white, has been wrapped in the Inozetek spectrum also.
Additional interior highlights include a suede dash cover by Hansshow, a center console overlay, and an armrest painted white to match the seats. The technological upgrades are impressive, with a 10.2-inch touchscreen entertainment system in front of the driver and a 7.2-inch rear touchscreen carbon fiber entertainment system for rear passengers, both by Hansshow. The RGB interior lighting throughout by EV Base adds an ambient, futuristic feel to the cabin.
Inside, every surface, from the carbon fiber yoke steering wheel to the door panels, is enveloped in the limited edition Inozetek Spectrum color. The seats, draped in white and topped with a ceramic coating, along with the custom subwoofers and amplifiers, strike a balance between comfort and entertainment. The dual touchscreen entertainment systems, one for the driver and another for rear passengers turn each journey into an immersive experience, and update the interior, mimicking the brand new “Project Highland” Tesla Model 3.
The Art of Customization Bucky’s approach to customizing OUTAGAZ transcends mere aesthetic enhancement. It’s about challenging established norms and embracing the untapped potential of EVs.
“These vehicles are more than just about low maintenance and high torque,” he explains. “They’re canvases for creative expression.”
This philosophy is evident in every modification, from the air suspension system that endows it with a distinctive stance to the custom interior that transforms every drive into an event.
Bucky’s journey has been bolstered by the support of his family, friends, and car clubs like Acrophobia and Ruined EV car clubs. His future plans include continuing to customize OUTAGAZ, ensuring that it remains a dynamic representation of his evolving vision and the possibilities within the realm of electric vehicles.
For those contemplating a similar project, Bucky’s advice is straightforward yet impactful: “Go all in.”
He advocates for the unique appeal of customizing electric cars, encouraging others to explore and innovate in this relatively new area of automotive customization. Bucky Howard’s Model 3 is more than a modified Tesla; it is a rolling proof of the boundless potential of EV customization. It is the symbol of the harmonious fusion between advanced technology and personal expression. As Bucky cruises the neon-lit Strip of Las Vegas, OUTAGAZ is not just a vehicle; it’s a vibrant palette of innovation and passion, echoing the spirit of its city and creator that resonates with the ethos of its environment and the vision of its owner. Viva l’Outagaz!
SPECS
Owner
Bucky “Shotty” Howard
Location: Las Vegas
Model: 2020 Tesla Model 3 SR+
Vehicle Name: OUTAGAZ
Club Affiliation: Acrophobia, Ruined EV
Time to build: Three years
Cost to build: $50K and rising
Occupation: Music artist, YouTuber, Sales professional
Motor & Drivetrain
Motor Drive Unit Year, Make, Model: 2020 SR+ RWD
power: 208kW/279 Hp
Torque: 450Nm 332Lb-ft
Voltage: 350V
0 to 60 time: 5.3 seconds
Chassis/Suspension
Installation Shop: MadHouse Customs, OMC Old Man Customs, The Rod Shop, The Fab Lab
Air ride system: Universal Air Suspension solution series
Air management system: Airlift Performance 3 PM Management
Shocks: Universal Air Suspension shocks
Other
Custom hard line frunk display, two Viar 485 compressors wrapped in Inozetek, chrome tank from bag riders wrapped in Inozetek, hardlined together
Wheels, Tires & Brakes
Rims: Tsportline TS5 20” x 8.5 painted gloss black
Tires: Falcon 245/35R20
Body/Paint
Color: Limited edition color by Inozetek Anti-Social Social Club – Spectrum
Exploring the Significance of Electrical Bonding in EVs
As cooler months descend upon us, so do tacky wool sweaters. If you’ve had the opportunity to wear one for an ugly sweater party, you may have also experienced becoming a conduit for unexpected static shock as you grabbed the serving spoon in the punch bowl. While unpleasant, this phenomenon can teach us a great deal about electric vehicle safety systems that can keep builders or repairers working on them safer from electric shock.
What is Potential Equalization?
When you felt that jolt of electricity passing through your hand and onto the metal serving spoon, you were experiencing a “potential equalization” across two different materials. You—and the thing you touched—were at two different electric potentials, or “voltages.” When you and that spoon got close enough together, the shock you felt was the differing potentials becoming equalized. Had you and the spoon been at the same electric potential, the shock would have never occurred.
To protect EV components and the people working on them, potential equalization is essential. Bonding is a type of potential equalization where one intentionally electrically connects all exposed metal items not designed to carry electricity as protection from electric shock by keeping these metals all at the same electric potential. In the context of EVs, this includes conductive components like the chassis, frame, body, and external housings. This prevents potential differences that could occur due to different components being connected to different electrical sources or having different resistances. Through potential equalization, we can minimize the risk of electric shock, arc formation, and electrical damage within the vehicle.
What Does Electrical Bonding Look Like in an EV?
Electrical bonding can come in different forms. In many cases, bonding is achieved by simply mounting the conductive housing of a high-voltage component directly onto the metallic frame, chassis, or firewall of the vehicle.
In other cases, a bonding cable may instead be run from the high-voltage component housing to the chassis. The ReVolt crate motor has a bonding strap that connects the main body of the motor to the chassis of the car.
The Cascadia Motion inverter has a marked hole with a chassis ground symbol in the top right hand corner to indicate the placement of a bonding cable.
Often, you will find both bonding approaches in a vehicle. In the EV training bench, all component housings are bolted to the metal tabletops. Bonding straps are then used to bond the different parts of each bench together.
How Does Bonding Keep Us Safer from Loss of Isolation Faults?
EVs, just like gas cars, have low-voltage circuitry that grounds to the chassis. The high-voltage circuitry, however, is a “floating system,” in that its own ground is completely isolated from the chassis. Any high-voltage circuitry will be covered in electrical insulation that creates a substantial degree of resistance, often on the order of megohms (millions of ohms). In the case of an accident where the housing or insulation from the high-voltage system became damaged, the HV leakage would energize whatever it touched to the same potential. So even if a technician isolated the HV system, they could still be at risk of making contact with two deadly differences in potential. With proper bonding, however, that damaged housing would bring anything else it is bonded to at the same potential, limiting the chances of such an encounter.
In many cases, bonding is achieved by simply mounting the conductive housing of a high-voltage component directly onto the metallic frame, chassis, or firewall of the vehicle.
In addition to limiting the amount of materials with different electric potentials, good bonding allows devices, like ground fault monitors, to check component housings and the chassis for high-voltage leaks. If a high-voltage component is not properly bonded, or the cable it is bonded to has oxidized over time, the ground fault monitor would not be able to notice that a dangerous high-voltage leak was occurring.
How Can You Check Bonding?
In addition to visually inspecting bonding cables and mounting points for corrosion, dirt, and poor contact, OEMs may provide instructions to check bonding using a special tool called a milliohm meter. The Hioki REM3548 portable DC resistance meter is a common tool used in shops involved in EV collision and repair.
Milliohm meter probes have four tips rather than the typical two seen in a digital multimeter. It sends a one-amp current through one probe, while the other measures voltage. This allows it to detect tiny resistance variations on the order of micro-ohms, or millionths of an ohm, resistances that are far too small for a digital multimeter to notice. For example, placing the milliohm meter terminals as close together as possible on a piece of aluminum yielded a resistance of 0.0066 milliohms.
But what kind of resistance values should you be looking for to ensure good bonding? As a baseline, a 1-meter (~3 foot) long cable has an internal resistance of about 1 milliohm. The United Nations Economic Commission for Europe, Regulation 100 (UNECE-R100) provides technical guidance safety requirements with regard to fitting parts on a vehicle with an electric powertrain. It ties the 1-milliohm-per-meter standard as a guiding reference for bonding. If the resistance reading were much higher than this standard, a technician has reason to suspect that the component’s bonding needs improvement.
What Can I Do As a Builder or Shop Owner?
Incorporate bonding cables or mounting points into your design: If you are considering placing HV components on top of insulated materials, like certain paints, wood, carpet, or plastic, make sure you are considering how you will either install a bonding cable or create direct metal contact between your component’s housing and the frame of the vehicle.
Visually inspect components you repair or install: Examine the vehicle for any missing bonding cables or corroded connections that can prevent good bonding.
Use a milliohm meter: If you are repairing or building an EV for a customer, use a milliohm meter while referencing the manufacturer or international safety standards for bonding.
Documentation: If it wasn’t documented, did it really happen? Take before/after photos of HV components you remove/install and note instances of improper bonding. Collect milliohm meter readings into documents that you can refer back to for that customer.
The Growing Impact of EVs in the Aftermarket Scene at SEMA
In many ways SEMA is the annual pulse check of the aftermarket automotive industry. Exciting new products, mind-blowing builds, and major automotive personalities can all provide insight on the state and trajectory of the industry.
Over the past few years, the converted-EV presence at the event has grown significantly. This year, in the “Future Tech” zone, more than 15 exhibitors showcased parts, tools and educational offerings that catered to this emerging technology. Additionally, over 60 electric swapped vehicles were on display, ranging from European sports cars such as a Jaguar E-Types and Porsche 911s, to American classics such as Ford F-100s and Chevy Camaros, all of which had been converted to push some serious current instead of burning gasoline.
Not only does the aftermarket EV industry now have major buy-in from event organizers (such as SEMA), tier-one manufacturers, and OEMS, but automotive media is starting to take notice as well. Over the course of the show, automotive legends such as Richard Rawlings, Chip Foose, and Ben “The Stig” Collins, could all be found in the Future Tech zone checking out the next chapter in hot-rodding. Long-time gas-powered enthusiasts are realizing the performance potential and creative opportunities that lie within electric power.
If there is one key takeaway, the electrified presence at SEMA 2023 indicated an increasingly bright future for the aftermarket EV industry. We are excited to continue to cover the emerging technologies, builds, events, and culture that will steer this huge industry disruption, and we look forward to having you along for the ride.
Electrifying a Classic: An Electric 1969 Subaru 360
From Nursing Books to Garage Tools: A Mechanic’s Triumph in No-Nonsense Retrofit
During my time at The Vault, a classic car dealership situated in Jackson, Mississippi, I embarked on my journey with a 1969 Subaru 360. This peculiar car stands out among the array of rare and expensive classics and exotics that graced the shop. As I juggled being a full-time nursing student, my boss, JD Pass, accommodated my schedule, allowing me to work around classes and clinical commitments. This unique flexibility enabled me to nurture my passion for classic cars and mechanics while pursuing my education.
My association with The Vault extended throughout my time in nursing school and continues sporadically to this day, with occasional visits to lend a hand in the shop. Amidst a treasure trove of automotive wonders, the little 1969 Subaru 360 caught my attention. It arrived at the shop with a dormant engine and ineffective brakes. This modest and unassuming car would soon become one of my favorites.
Upon completing nursing school and finding myself with disposable income, an opportunity presented itself on the Facebook Marketplace—a project car, a 1969 Subaru 360, in need of revival. After parting with $1,200 and undertaking a four-hour road trip, the little car became part of my life. At the outset, my intention was to restore the original motor or locate a suitable replacement engine. Yet, the scarcity of hard-to-find components for the original powertrain led me down a different path.
In my Uncle Earl’s workshop, which housed dormant Taylor Dunn and EZGO vehicles, my quest for an alternative solution began. These neglected electric vehicles became my experimental ground. A journey of trial and error ensued, eventually giving rise to what I now refer to as the Electric 360.
The original Subaru 360 engine presented a plethora of issues—missing parts, bent rods, and a piston with a hole, among others. Salvaging the crankshaft bearings and removing the piston rods marked the starting point. The electric motor took the place of the cylinders, connected by a chain to the crankshaft. The motor mounting plate, sourced from the Taylor Dunn, was meticulously aligned with the Subaru block. Custom-made sprockets from Motion Industries in Jackson, Mississippi, upheld a 1:1 ratio between the motor and the crankshaft. A specially crafted bracket supported the electric motor’s weight, occupying the space previously reserved for the cylinders. Retaining the rest of the Subaru drivetrain maintained the car’s original essence.
My foray into electrical engineering was aided by rewiring the entire vehicle harness, a task facilitated by my father’s background as an electrical engineer. A 36V to 12V converter powered a fuse block that controlled the lights, signals, and wipers. With the back seat removed, I constructed a frame to house the batteries and essential controls, expertly upholstering a box to conceal them. Sheetmetal repairs and extensive bodywork occupied three years, culminating in a satisfying paintjob. Reassembly proved more straightforward, and the transformed car emerged in all its glory.
Through constant research during the build, I identified potential upgrades for future street legality. While this venture was undoubtedly marked by trial and error, it has shown me the remarkable potential of electric conversions.
Over the past three years, the car has been showcased as a “work in progress” at numerous local car exhibitions, including the Southlife Car Show in Pearl, Mississippi. The vehicle has garnered a local following due to its unconventional charm and evolving transformation. This weekend, the car will make its debut as a completed project at the same show where it initially captured public attention.
Notably, the car’s presence extended to television, featuring on “Stacy David’s Gearz.” This platform spotlighted the car’s gradual evolution, an inspiration for others to embark on their garage-based projects. My Subaru 360’s potential to encourage others to pursue their automotive dreams is a rewarding outcome.
Reflecting on the build process, wiring emerged as the simplest task. Drawing from my familiarity with electrical systems and old cars, I managed the 36V motor circuit akin to a golf cart setup and the 12V circuit for lighting and wipers. Electrical complexities were mitigated by my upbringing and experience, streamlining this aspect of the conversion.
Although time was a formidable adversary, the journey was sustained by support from fellow Subaru 360 owners and invaluable assistance from my dad, Uncle Earl, and Dan Dearman.
While the present build might rely on outdated technology, the potential for modernization looms large. Visualizing the car with modern batteries, motors, and controls ignites excitement for a future upgrade. However, budget constraints temporarily temper such aspirations. The gradual evolution of EV technology will hopefully pave the way for more accessible upgrades, enabling projects like mine to reach new heights.
A fervent advocate of home-based innovation, I encourage others to embark on their own creative journeys. Whether transforming a dilapidated go-kart, rusted car, or forgotten dirt bike, the magic lies in making disparate elements harmonize. Drawing from personal experiences and the philosophy of building championed by figures like Stacy David, I champion the idea that the pursuit of a project need not be constrained by its shine or cost. Witnessing individuals derive pride from their creations, irrespective of their scale, is immensely rewarding.
Perseverance and embracing trial and error form the cornerstone of successful projects. Venturing beyond factory specifications demands a blend of courage and patience. The “Keep It Simple Stupid” approach guided my project, promoting a focus on fundamental simplicity. With each step taken, knowledge expands, and capabilities grow. Initiating with manageable undertakings paves the way for improvements and innovations over time.
SPECS
Richard Rieger II
Location: Brandon, MS
Year, Make, Model: 1969 Subaru 360
Amount of Time to Build: Three years
Cost to Build: $3,000 (car, battery, parts, and paint)
Occupation: Registered Nurse
Motor & Drivetrain
Motor Swap Performed By: Richard Rieger II
Motor Drive Unit Year, Make, Model: GE 5BC49JB305 from a Taylor Dunn B248 Utility Truck
Power: 10 hp
Voltage: 36V DC
Max RPM: 2,800
Max Continuous Power: 275 amps
Motor/Transmission Mounts: Factory
Control System and Software: Curtis 1204-009 from EZGO golf cart
0 to 60 time: Depends on how steep the hill is … downhill, that is (max speed on flat ground is only about 30 mph)
Vehicle Weight: 1,800 pounds
Battery System & Charger
Pack Design: Six 6V Duracell GC2
Cell Type: Flooded deep cycle
Module Manufacturer and Configuration: EZGO golf cart with Curtis 275 amp controller
Battery Capacity (in kilowatt-hour): 215AH
Battery Locations: Behind front seat
City Range: 25-30 miles
Charger kW Charge Rate: 18-amp charger
Charger Location: Charge port where gas tank fill used to be; external charger
DC Fast Charging: 18-amp charger
Chassis/Suspension
Installation Shop: Richard Rieger II at home
Chassis: Factory unibody car
Rear Suspension Setup: Factory independent torsion bar suspension
Control Arms: Factory
Spindles: Factory
Springs: Factory
Shocks: Factory
Track Bar: Factory
Wheels, Tires & Brakes
Wheel: Factory split rims and hubcaps
Tires: 5.00-10 Deestone
Front Brakes: Factory drum, but completely rebuilt; shoes were relined, new seals, new hoses (actually GM disc brake hoses from JEGS), and I made new hard lines throughout the entire car
Rear Brakes: Same as above
Gears/Ratio: Factory 4-speed transmission
Axles: Factory
Body/Paint
Paint Shop: Richard Rieger II in garage
Color: Fiat Azzurro Cappellini
Wheelwells: Factory
Body Mods: Factory … with a lot of rust repair done with scrap sheetmetal from a ’57 Chevy
Headlights: Factory, 7 inches
Taillights: Factory 1157
Glass: New windshield from a Subaru 360 enthusiast, Billy Paul, who made a limited supply run; windshields are not reproduced by any company and any 360 owner knows the windshield is the hardest part to find on these cars
Rubber Moldings: Factory, except aftermarket windshield gasket supplied by another Subaru 360 enthusiast, Anthony Cano
Interior
Install Shop: Richard Rieger II in garage
Seats: Factory, hopefully soon to be reupholstered
Gauges: Factory, except a 36V battery gauge was added under the dash from Amazon
Steering wheel: Factory
Special Thanks
Richard Rieger, Earl Scallorn, Dan Dearman, Roddy Merritt, Zack Munger, Sylvia Rieger, David Rieger, Frances Rieger, Jackie Scallorn, Cody Russell
In a world increasingly transitioning towards sustainable transportation, the intersection of classic cars, exhilarating driving dynamics, and cutting-edge electric vehicle technology might seem unlikely. However, the innovative minds at Fellten, originally known as Zero EV, have proven that classic car enthusiasts can have it all, thanks to the company’s bolt-on, plug-in solutions. As Fellten celebrates its 5th anniversary, let’s meet this British-Australian conversion system and battery pack manufacturer and discover its journey in electrifying the classics.
Promising Niche
It began in 2018 with a passionate team driven by a common goal: to solve the electric conversion problem. With the rise of electric vehicles, converting classic cars to electric power started to become a niche yet promising industry, and Fellten creators Chris Hazell and Alex Dawood recognized the opportunity.
At its core, Fellten designs, engineers, manufactures, and distributes OEM and aftermarket battery packs, electric motors, and complete bolt-in, plug-in systems. Its influence spans the UK, Australia, North America, and Europe, where its commitment to excellence shines through as it sets industry standards for quality, safety, reliability, and production volume.
Driving Innovation
What sets Fellten apart in the industry, both then and now, is its unwavering commitment to innovation and quality. The Fellten team is comprised of seasoned professionals with extensive experience in electric vehicle technology, battery systems, vehicle conversions, engineering, and production.
This expertise has led to groundbreaking developments, including CCS Rapid Charging, Vehicle to Load bi-directional charging and, complete skateboard-chassis manufacturing. Its focus on producing low-volume series battery packs and conversion systems ensures personalized solutions tailored to customer needs.
Fellten prioritizes the highest standards of quality and reliability. Its strategic partnerships with trusted OEMs have elevated the company to Tier-1 supplier status. It actively shapes emerging electric vehicle industry benchmarks, such as EVTEC, through its involvement in industry associations and dedicated training programs for system installation and EV maintenance.
Global Reach and Future Plans
Headquartered in Bristol, UK, and Melbourne, Australia, Fellten’s global presence extends beyond these two locations. Fellten’s future expansion plans include distribution into the US market through Legacy EV and a few more projects in the pipeline. The company’s growing manufacturing capacity and dedication to quality control processes show it can meet the demands of a booming market.
Diverse Product Portfolio
Fellten’s product portfolio encompasses a wide range of markets, including truck and 4×4 conversions, Classic Minis, Porsche 911s, Land Rover Defender conversion systems, and complete skateboard platforms. Its foray into the marine industry is equally promising, with EV Drives enabling cleaner and quieter marine transportation.
Key Partnerships and Sustainability
Besides catering to OEMs like BMW/MINI, Fellten also collaborates with high-end boutique manufacturers like Connecticut-based Sacrilege Motors, known for their iconic Porsches. Fellten’s expertise in electric powertrains has earned praise from Sacrilege Motors, who rely on Fellten’s technology to preserve the classic feel of their Porsches while enhancing performance and reducing environmental impact.
“Fellten is the best partner to power our iconic Porsches electrically,” says Phil Wagenheim, Sacrilege CEO. “It has the utmost expertise, experience, and products to ensure a successful conversion process. It will help us preserve the classic feel of our Porsches and enhance their performance while also reducing our environmental impact.”
Fellten’s remarkable journey, from a desire to solve the electric drive problem to becoming a global leader in EV conversions, is a testament to its team’s innovation, commitment to quality, and dedication to sustainability. As it celebrates its first half-decade, Fellten is not only electrifying classic cars, but also driving the future of the retrofit industry and community.
Fellten’s Main Product Markets
Universal Battery Pack
Off-the-shelf 55-kWh (UBP55E), sealed steel box, plug-and-play ready, with integrated Orion BMS, active cooling, safety disconnect, and R100.1 compliant. Ideal for engine bay installation.
Classic Mini Conversion Systems
Complete, bolt-on, plug in, fully reversible 19-kWh conversion system (8.0 second 0 to 60, 72 kW/97 hp)
Porsche 911 Conversion Systems
Complete, bolt-on, plug in, fully reversible 63-kWh conversion system. (4.5 second 0 to 60 328 kW/440 hp)
Land Rover Defender Conversion Systems
Complete, bolt-on, plug in, fully reversible 55/82/110-kWh conversion system (several drivetrain options from 225 kW)328 kW/440 hp )
Complete “Skateboard” Platforms
Fellten’s skateboard chassis is a versatile EV platform designed for classic car-inspired vehicles. It offers a low center of gravity, front and rear crush zones, a 350V, 55-kWh flat replaceable-cell battery pack, a 7kW AC and 150kW DC CCS fast charger, a 200kW rear motor, dual-zone thermal management, limited slip differential, regen, advanced suspension, ABS disk brakes, and a proprietary software platform for vehicle monitoring and updates.
Zonic Motor Range
Fellten established Zonic Motors to introduce top-notch 350V nominal motors to the industry. These enable advanced high-voltage electric conversions capable of DC ultra-rapid charging. The Zonic motor range comprises three models (70, 120, and 180kW outputs) for compact to high-performance vehicle and marine applications.
Fellten: A Shocking Tale of Electrifying Evolution
In the dynamic world of electrifying classic cars, the story of Fellten (formerly Zero EV) is nothing short of impressive. From its humble beginnings in 2018 with just two passionate individuals at the helm, to becoming a global powerhouse in electric vehicle conversions, Fellten’s journey shows constant innovation, passion, creativity, and a touch of Hollywood flair.
2018 – The Genesis
(Staff: 2)
The story begins with Chris Hazell and Alex Dawood, the dynamic duo behind Fellten, located near Bristol, UK. Chris, with a background in event production and generator companies, and Alex, an industrial design graduate with a penchant for EV conversions, joined forces. Together, they create their first reversible conversion system. They shared their findings online, laying the foundation for what was to come. Chris, not content with a mere proof of concept, converted a Nissan R32 Skyline. The result? A tire-scorching sensation that wowed audiences across Europe. Hollywood came knocking, seeking electric movie cars, and the Fellten team delivered.
2019 – First Complete System
(Staff: Fellten: 3 • Jaunt Motors: 2 • Total: 5)
In 2019, Fellten expanded to larger premises in Bristol, UK. It unveiled its first complete system, an entirely in-house developed solution that included tools and training for conversion specialists. Meanwhile, on the other side of the globe, Dave Budge and Marteen Burger established Jaunt Motors in Melbourne, Australia. They specialized in crafting stylish electric off-road vehicles, setting the stage for a sustainable adventure.
2020 – Porsche 911 Solution
(Staff: Fellten: 7 • Jaunt Motors: 5 • Total: 12)
Fellten took a giant leap forward in 2020, designing and manufacturing new systems in Great Britain. They also offered white-label solutions to electric conversion specialists worldwide. But the pièce de résistance was the launch of its revolutionary Porsche 911 complete bolt-in system. The world of film and entertainment remained eager for fantastical converted vehicles, and Fellten didn’t disappoint.
With 2021 came a year of design and development for Fellten, culminating in the launch of its second bolt-in system dedicated to the Classic Mini, developed in conjunction with BMW/MINI and MiniSport. They embarked on converting another British icons: the Classic Land Rover Defenders, forging a close collaboration with Jaunt Motors.
In 2022, Fellten’s dedication to quality led them to achieve ISO accreditation, making it the only company with three ISO compliances in the industry. It expanded its training offerings, providing government-sanctioned courses to up-skill staff working with electric vehicles. As they expanded globally and realized the synergy in merging, Fellten and Jaunt Motors became one entity, aptly named Fellten (Welsh for lightning).
Fast forward to 2023, and Fellten stands at the forefront of the EV conversion industry. It offers model-specific and universal conversion systems across Australia, North America, and Europe, setting the bar for quality, safety, reliability, and volume. Its UK production facility is geared up to deliver systems in the hundreds for its approved conversion specialist international network.
Breaking Barriers with Innovation: Neil Tjin Edition Ford Mustang Mach-E
Neil Tjin Unleashes the Power of Innovation with His SEMA Award-Winning Mach-E
The story behind the Tjin Edition Ford Mustang Mach-E California Route 1 showcases the passion and dedication of a true automotive enthusiast. Neil Tjin from Laguna Niguel, California, has been immersed in the automotive industry since 1996, turning his hobby into a full-time job and a lifelong passion, building award-winning show EVs and electric trucks—and organizing one of the coolest EV events in the US: Electrify Expo’s Showdown.
“I am a huge fan of the EV space, and even though it is still new and upcoming, it is freaking awesome,” Neil says. “And being the director of the showoff, I get to meet fellow EV builders, we get to set the trends for the future, and I get to see cool EVs across the country. The space is hot, new, and exciting, just as I like!”
Having worked with Ford since 2009 on SEMA cars, in early 2020 he was again approached by the Blue Oval team and designers to take on the challenge of building and designing the all-new Mach-E for the prestigious Las Vegas trade show. The project kicked into high gear in August of that year as the car was delivered and parts started pouring in. With relentless determination, Neil and his team worked tirelessly for two months. Finally, the Tjin Edition Mach-E was completed, proudly occupying the spotlight at the legendary blue-carpeted Ford booth at the SEMA Show, where it won Best of Show Ford at SEMA! Winning was historic as the Tjin Edition Mach-E became the first-ever EV to clinch this esteemed honor.
As you lay your eyes upon the Tjin Edition Mach-E, you can’t help but be captivated by its flawless custom paintjob. With a striking orange hue expertly applied by Neil’s brother, Gene, who runs Tjin Paint and Body, this immaculate paint job is enhanced even more by the BLK LBT DTL ceramic coating. The Vossen ERA-3 wheels measuring a jaw-dropping 22×9.5 inches and wrapped in Yokohama Parada Spec X also bring a new dimension to the Mach-E.
Ridin’ on Air
But it doesn’t stop there. Neil has gone above and beyond, fitting his Mustang with an Air Lift suspension system meticulously installed Mr. Alex from Hoppo’s Suspension. With Air Lift struts and Viair compressors working harmoniously, the Tjin Edition Mach-E glides effortlessly along California freeways in comfort. To top it off, the Baer 6S 6-piston front and rear brakes guarantee precise stopping power, instilling confidence in any driving situation.
Step inside, and you’ll be greeted by two custom white Recaro seats adorned with teal highlights, creating an ambiance of pure elegance. Neil doesn’t skimp on the details, outfitting the interior with custom orange Seatbelt Planet seatbelts and a selection of electric two-wheeled rides from Razor and Super73 e-bikes, which is mounted to the rear of the Mach-E witha custom 1up bike rack. It’s clear that every aspect of the Tjin Edition Mach-E has been carefully crafted to create a cohesive package.
Daily Driver
Since the Tjin Edition Mach-E has become a fixture in its creator’s short-term and long-term plans, Neil has been driving the Mach-E for the last 20 months as his daily driver. It has also become a regular participant in West Coast events and various automotive gatherings, including the LA Auto Show and the Electrify Expo Showoff in Long Beach, California.
Building the Mach-E was no easy task. Numerous challenges existed as the Mustang was a brand-new vehicle at the time of the build with little aftermarket equipment. Neil humorously admits that nothing was easy, but if he had to choose, the full-color change paintwork stood out as a relatively smooth process, thanks to the car’s pristine condition. However, every other aspect posed a challenge since nothing was readily available for modifications.
Great Tips
Neil emphasizes the importance of taking your time when tackling a similar project, conducting thorough research in advance, and, most importantly, having fun. With the EV aftermarket becoming more accessible, the possibilities are limitless, and the Ford Mustang Mach-E presents itself as an incredible platform with immense potential—just like its grandmother in the ’60s!
Brett Hunsaker’s Visionary EV Creation Takes the Car Scene by Storm
Las Vegas is known for its glitz and glamour, but hidden among the neon lights and bustling streets is a ground-breaking masterpiece turning heads in the local car scene and EV modification world. Meet “Karma,” a 2020 Tesla Model Y brought to life by the visionary builder Brett Hunsaker.
Brett has always been drawn to pushing the limits of automotive customization. So, with a background in mini-trucks and lifted rigs, he set out to infuse that unique style into an electric vehicle. And from the moment he laid eyes on a Tesla Model Y, he knew it would be the perfect canvas for his project.
As the saying goes, Rome wasn’t built in a day, and the same can be said about Brett’s remarkable build. The project began before the Tesla even arrived, albeit initially on a way less extreme level of modifications. With a few parts patiently waiting at home, Brett eagerly anticipated the moment he would be united with his ride. Little did he know at the time just how much this project would snowball.
Originally intended to be a slightly modified practical work car, it quickly became apparent that driving a close-to-stock vehicle was not in Brett’s DNA. Instead, the desire to transform the car into something unique and reflective of his style took hold. So, less than a 1,000 miles after taking delivery, the Las Vegan decided to go “all-in,” including dropping the Y to the ground with a never-seen-before air-ride setup.
Some might question why Brett chose a Model Y for his ambitious build, given the perception that SUVs inherently differ from more road-focused counterparts such as the Model S Plaid or Model 3 Performance. However, Brett is quick to dispel this notion. In his eyes, the Y is not fundamentally different from the 3; it does share a majority of parts—yet the Model Y, in general, had then been significantly less modified, especially in the air-ride department.
Karma is based on the Performance version of the Model Y, sporting a dual-motor setup; it delivers an insane 393kW/527hp and 660Nm/487 lb-ft. With a lightning-fast acceleration time of just 3.5 seconds from 0 to 60 mph, it merges the worlds of electrification, cool family wagon capabilities, and exhilarating performance.
From the moment you see Karma, you’re captivated by its brushed black steel wrap, meticulously applied by the talented hands of Mario Baratta at Madhouse Customs.
Every element of Karma’s exterior has been carefully curated to perfection, including the tinted headlights, Hansshow taillights, sleek carbon-fiber hood, and unique one-off honeycomb vinyl design on the glass roof—stunning from the inside and slightly reducing sunlight exposure—perfect for the Nevada desert climate.
Masterful Suspension
But Karma’s beauty isn’t just skin-deep. Brett turned to the skilled team at Shawn Robinson’s Old Man Customs for the chassis and suspension modifications to ensure the perfect balance between style and functionality. They worked tirelessly to create a unique setup, allowing Karma to be the first Model Y to lay its body on the ground. It consists of an Air Lift Performance air-ride system paired with Air Lift shocks, MPP upper control arms, and a custom sway bar—they guarantee an unrivaled smooth ride and superb control on twisty roads just outside Sin City. Last, hidden in the frunk, we find a custom-painted FLO air tank to match the wheels. It sits on custom fabricated mounts and is coupled to two Viair 480 air compressors, wrapped in the same vinyl as the car’s exterior.
To visually slam the Y even more, Brett opted for bumper lips and extensions, all wrapped in body color with a bright copper strip adorning the rear spoiler and side camera covers. Of course, a genuinely great car deserves equally impressive wheels, and Brett didn’t disappoint. Karma proudly rolls on custom-made, two-tone, 21-inch Electric Performance rims wrapped in Michelin Pilot Sport 4 tires, which provide excellent grip. The stock Brembo performance brakes have been meticulously painted in the striking copper hue. They are highlighted by BlamfLED off-road lighting wheel rings. For good measure, Brett coupled the latter with Lighting Trendz underglow and lights.
Inside Job
Stepping inside Karma reveals an interior that seamlessly blends luxury and innovation. Andrew Evens, Mike Rios at Fabricated LV, and Mario at Madhouse Customs worked their magic to transform the interior into an ultra-bright cocoon. The stock front seats received additional white leather back panels for a monochromatic finish, perfectly matching the center armrest, dashboard finisher, and the plethora of painted plastic trims. Door card inserts, ceiling, and pillar trims were elegantly wrapped in white suede. Then comes the piece de resistance: the custom-made steering wheel from Unleashed Customs. It sports white perforated leather and forged carbon and perfectly complements the interior’s flashy-yet-classy ambiance.
Karma’s interior isn’t just about comfort; it’s a symphony of sound. Brett spared no expense in creating an audio system that surpassed expectations. Two 10-inch Wolfram Audio subs, housed in a custom-tuned box, deliver chest-thumping bass, accompanied by a Wolfram 3500.1 sub amp and two Arc Audio 4-channel amps. In addition, the Audio Control DSP 810, housed in a custom-lit, molded amp rack, ensures precise control over every note, even when cranked to 11.
Trendsetter
Karma has already left an indelible mark on the modified OEM EV scene. Unforgettable experiences and numerous appearances at prestigious events have marked the journey of this unique EV build. Brett has showcased his creation at the Tesla Takeover twice in California, the Lone Star Throwdown in Texas, and multiple shows in Utah. However, it is in Las Vegas where his masterpiece has left an enduring mark, racking up an impressive collection of awards, including the coveted “Best of Show.” This build has also garnered recognition at Mint Truck style shows, securing multiple top 50 and 30 medals.
Coming from a background rooted in mini-trucks, Brett aimed to infuse that distinct style into a Tesla, creating a one-of-a-kind fusion. However, as with any ambitious project, challenges were bound to arise. Brett’s passion, dedication, and the support of his club affiliation, Relaxed Atmosphere, became his best allies in overcoming these obstacles. The audio system design and installation were particularly tricky.
Along the way, Brett discovered some invaluable tips. Planning and anticipating potential issues proved instrumental in avoiding costly and time-consuming rework. The importance of doing things right the first time, even if it meant a slightly higher initial investment, became evident as he encountered the complexities of redoing certain aspects—then again, haven’t we all over the years?
Brett emphasizes the significance of having a clear end-goal in mind. Undertaking substantial modifications as a collective effort, rather than piecemeal changes, helps streamline the process and ensures a cohesive final product. In addition, it is crucial to pay attention to how each modification affects the overall functionality of the vehicle. He has certainly perfected the art of modifying a Tesla.
Installation Shop: Shawn Robinson at Old Man Customs
Chassis: Custom fabbed to be the first to lay the body on a Model Y
Rear Suspension: MMP rear camber arms
Control Arms: MPP upper control arms
Air-ride System: Air Lift Performance
Air Management System: Air Lift Performance (with custom face plate)
Shocks: Airlift Performance
Track Bar: Custom sway bar end links
Other: FLO air tank (custom painted to match the wheels with custom fabricated mount), Viair dual 480 air compressors wrapped in the same vinyl as the exterior of the car
Wheels, Tires & Brakes
Front Rims: Electric Performance wheels 21×9 two-piece (custom two-tone color)
Front Tires: Michelin Pilot Sport 4 in 255/30R21
Rear Wheels: Electric Performance wheels 21×10.5 two-piece (custom two-tone color)
Rear Tires: Michelin Pilot Sport 4 in 255/30R21
Front and Rear Brakes: Stock Brembo Performance with custom copper paint
Body/Paint
Color: Brushed black steel wrap by Avery Denison
Wrap Installer: Mario Baratta at Madhouse Customs
Bumpers: Stock, with lip and extensions and wrapped
Headlights: Tinted
Taillights: Hansshow
Glass: Ceramic tinted
Body Kit: Rear skirt
Other: Carbon fiber hood and carbon fiber rear wing. Lighting Trendz underglow and BlamfLED off-road lighting wheel rings
Interior
Install Shop: Andrew Evens and Mike Rios at Fabricated LV and Mario at Madhouse Customs
Seats: Stock white with added rear white leather, along with white suede wraps on the ceiling and pillars
Gauges: Wrapped screen and dash pieces and console in copper and forged carbon
Steering Wheel: Unleashed customs in white leather and forged carbon
Radio Head Unit: Stock
Subwoofers: Two 10-inch Wolfram subs custom-tuned box and lighted with design features
Amplifiers: One Wolfram 3500.1 sub amp, two Arc Audio 4-channel amps, audio control, DSP 810 in a custom-lit and molded amp rack
Speakers: Amplified stock speakers and JY Power lithium battery
Custom-made ceiling design in a honeycomb pattern
Steering column wrapped in forged carbon
Matching floor mats
Sponsors and Special Thanks:
Sponsors: Old Man Customs Fabricated LV, Madhouse Customs, JY Power, BamfLED off-road lighting, and Wolfram audio
Thanks: First to my wife Kelli for being so supportive of my hobby, my Relaxed Atmosphere family, Shawn Robison, Andrew Evens, Mario Baretta, Travis Young
From converting your gas guzzler to an electric stunner to exploring the inner workings of Ken Block’s insane Hoonitron, we’ve got everything you need to know to get your EV journey rolling – and then some!
If you’re feeling stuck in the past, we’ll take you back to the present as we electrify classic vehicles with the best in-person training in the biz at Legacy EV.
Plus, get ready to go green with a vengeance as we unveil our top five builds from SEMA 2022, where the wildest EVs were on display.
We also look at the global electrification movement with stunning international feature stories as well as some awesome reader’s rides!
Terry Orr is a Canadian car builder who is passionate about hot rodding and EV conversions. Orr has taught himself how to do two electric vehicle conversions so far, a Ford Ranger and a Volkswagen Super Beetle, at his home in Calgary, Alberta.
He says, “it’s all about electric now. You’re trying to make your own cool, unique car, and make it better and faster than it was. That’s the essence of hot rodding.”
Orr started fixing up cars in high school in the late 1970s and early 1980s. After a couple of decades of hiatus, he returned to his native Calgary and started building cars again. However, it was EVs that soon caught his imagination. He bought a Nissan Leaf and discovered it was an excellent car with a good drivetrain. At the time, the whole EV conversion scene was taking off, and he needed a truck, so he was attracted to the compact, 1984 Ford Ranger, which he converted himself.
The Ranger now runs Tesla Model S battery modules and is at version 3.0 of development. Orr spent hundreds of hours online figuring out the details for each of his conversions. For the Ranger’s custom engine bay, he says, “I probably sketched it out 20 times. I started by approximating the whole engineering puzzle with pieces of wood as I figured out where everything would go.”
Orr credits his hot rod apprenticeship with helping to solve the many engineering challenges of an EV conversion. “I think it’s immensely important because it provides you with the understanding of how the car works,” he says.
For Orr, EV conversions are about creativity and challenge. He says, “It’s new, challenging and hasn’t gotten standardized yet. When people are doing EV conversions, everyone does it a little bit differently.”
Toyota To Convert Classics and older cars Into EVs
Akio Toyoda, head of Toyota, wants his company and all companies to fight global emissions. So his plan is for Toyota to convert gas-powered cars into electric or hydrogen power. First, hundreds of millions of ICE vehicles will be burning up fuel on roads for decades to come. And, it took a chunk of parts and labor to make them in the first place, so why let that go to waste? Would EV conversions of old cars really make sense?
“If only new cars are electrified, we aren’t going to be able to achieve carbon neutrality,” Toyoda said last week. “We also have to consider vehicle units in operation.” So the only way to see a big reduction in carbon emissions is to turn these old tanks into clean emitters with electric or hydrogen conversions.
For most countries, the electric alternative makes the most sense. Infrastructure definitely favors it over hydrogen. And it hasn’t been shown that hydrogen is really a good alternative, given the amount of processing, storage complexities, and extreme lack of hydrogen stations necessary for drivers to access.
To prove his point, Toyota unveiled two examples based on its wedgie AE86 hot hatches of the 1970s. One features an electric conversion, while the other opts for hydrogen. Toyoda says he knows developing his conversion concept is complicated. “There’s a competition to announce BEVs as quickly as possible now because of regulation,” Toyoda said. But he thinks, and the industry seems to be showing, that car buyers want to make a choice of several alternatives. And he says that Toyota’s targets are different of other automakers.
“They don’t have hybrids, they don’t have a global market, they’re not full lineup,” he said. “It’s a different competition and not the same players.” And right now, he only sees most shifting to develop new BEV models. “But the reality is that we cannot achieve carbon neutrality by 2050 simply by shifting all new-car sales to EVs. It is important to provide options for cars that are already owned.”
Automotive News found similar comparisons from CEO Takeshi Uchiyamada last year. At the time, Toyota was criticized for not embracing the electric wave more quickly. “In reality, there are many more cars on the street than new cars sold yearly,” Uchiyamada said. “We must make all cars carbon neutral, including those already on the streets.”
Source: www.motorbiscuit.com
Driving this e-Mini brings a Maxi grin on your face – and you can buy it! [VIDEO]
Our friends at TFLEV got the chance to test the ‘The Coolest Classic Mini‘ at the Goodwood Revival recently and just dropped this cool video(See bottom of page)
Their video gives excellent insight into what it takes to convert an EV. Still, more importantly, it shows OEMs are now very open to the idea of retrofitting classic cars.
French manufacturer Renault has unveiled their R5 Turbo 3E, hoping to bring a modern electric drivetrain and aggressive modern styling to an old 80’s platform.
The R5 Turbo was Renault’s hot hatch. It not only competed with the likes of the Volkswagen GTI, Mini Cooper, and Fiat/Abarth products of its time, but it defined French performance hatchbacks.
While the brand previously abandoned the vehicle and its tamer Renault 5 sibling, they are now looking to reintroduce it as an electric vehicle, one that they hope will be their “flagship model of the brand” and “[electrify] its history to better prepare its all-electric future in Europe by 2030.”
The concept vehicle has the chops to accompany its bold design. A dual motor system propels the vehicle’s rear wheels and is powered by a 42kWh battery, also placed in the rear between the motors.
The motors make a cumulative 380 horsepower and 516 pound-feet of torque, allowing the small hatchback to rocket from 0-60 in 3.5 seconds and hit a top speed of 125mph.
Besides these amazing specifications, the hatch defines itself with its countless camera mounts and aggressive aerodynamics. As if you hadn’t already noticed, the car’s rear is dominated by an enormous rear wing, complemented by side-mounted rear air ducts and an enormous rear diffuser.
Up front is a similar story. A large front splitter and a trio of front air ducts mean that the car has the aerodynamics of a block of swiss cheese. But this car is more than the sum of its parts.
It is an indication of the future of Renault. The brand is aggressive with its 2030 complete electrification goal, and this strangely aggressive performance hatch shows they are serious about moving forward. Count me as excited for the upcoming Renault 5 production version.
London only allows gas-burning vehicles into the center of the city if they pay a daily charge (up to $35 a day!), which if you have to travel through the city every day does add up becoming quite expensive.
And if you want to keep driving an older car, that just isn’t feasible for daily use, which is why drivers are choosing EVs, even those who want to drive classic cars.
Classics can, of course, be converted to full EVs these days, and some people are willing to pay quite a lot to have their classic cake and eat it without producing tailpipe emissions.
The London resident featured in this The Late Brake Showvideo initially looked at vehicles like a Nissan Leaf for his daily commute needs, but he ultimately chose the hard (and expensive) way to find a classic car and have it converted into an EV.
He initially looked at an Audi 100 coupe, but those proved to be too rare and expensive to make the conversion possible, so he settled on something much more common and easy to service – a 1975 BMW 1602, following Electric Classic Cars recommendations which was restored and given the 2002 look and in place of its 1.6-litre four-cylinder, it now has a 120 horsepower electric motor hooked up to the standard four-speed gearbox.
This isn’t one of those overly powerful EVs that have the ability to turn their rear tires into dust if you prod the go pedal too much – the owner wanted something with similar power to the original, although this is still pretty quick, with a zero to sixty time of around 7.5 seconds, more than adequate for negotiating London traffic.
The Dodge Charger Daytona SRT Concept teases the production of electric muscle car coming in 2024 amid promises it will beat all the performance metrics Dodge has laid down to date.
Sounds Like a Hellcat?
Yes, the Dodge Charger Daytona SRT is powered by batteries and electric motors, but air still swooshes through chambers and pipes for a rumble very similar to the roar of a Hemi Hellcat V-8 in today’s Dodge Chargers and Challengers. This sports the industry’s first exhaust system for an electric vehicle, producing a similar 126-decibel sound as the one coming from today’s Hellcat engine.
Dodge calls it “Fratzonic Chambered Exhaust.” When the Daytona converts electricity to power, air flows through the exhaust system and the sound produced through an amplifier and tuning chamber at the vehicle’s rear. You can see and feel the pressure from the exhaust coming out the back!
The Dodge Charger Daytona SRT Concept is designed to impress and appease its loyal customer base, many of whom are fundamentally opposed to EVs and all they stand for.
So, Dodge created an e-muscle car that looks mean and roars as loud as the Hellcats with supercharged Hemi V-8s that it will replace. “We believe we need the sound and experience,” says Kuniskis. That is why the car has a multispeed transmission and an exhaust note, so the driver can feel and hear the crack of the exhaust while shifting.
Dodge Charger Coupe
The concept, in Greys of Thunder dark glossy paint, has a clean design right down to the flush door handles and the absence of a rear spoiler. It is muscle without being a caricature, bold yet subtle. Head of Dodge Exterior Design Scott Krugger says his team started by designing a muscle car, not an EV, with a signature face, swept profile, and turbine-style 21-inch wheels.
It is also pure EV without a melted front for aerodynamics. Instead, true to the Daytona name, it has a nose cone, a patented R-Wing that allows air to pass through the front of the hood and enhance downforce while keeping a blunt Dodge profile that all but hides the headlights. There are carbon fibre intakes on both sides of the front and rear fascias for an air curtain to further improve aerodynamics. The front end is patented, as is the sound, which means these are intended for production.
Dodge is not revealing full specs and details yet, but we do know the high-performance SRT trim will be powered by a new 800-volt Banshee propulsion system. Lower trim models will have a 400-volt system.
The concept has standard all-wheel drive, so we know there are at least two motors, one up front and one in the back. AWD is also key to making the Daytona SRT quicker than the Hellcats that precede it, Dodge executives say. The Daytona Banshee has a multi-speed transmission with electro-mechanical shifting. Dubbed eRupt, the transmission does not deliver more power but allows the driver to feel each shift point, Kuniskis says.
The brand chief won’t reveal the number of gears or provide any performance figures yet. What we do know is there will be three power levels available, and customers can go to Direct Connection authorized dealers who will offer six more levels, all covered under factory warranty. All nine power levels were designed in advance, with the hardware in place for additional upgrades at the time of purchase or later.
Dodge promised it would be true to its muscle car roots when it embraced the electric car age, starting in 2024. The Dodge Charger Daytona SRT Concept, which looks production ready and has patents on its key features, appears to keep that promise.
Source: motortrend and Stellantis
OEM and retrofit specialist launch commercial retrofit vehicles solutions
Renault Group and Phoenix Mobility, a French commercial vehicle retrofit specialist have signed a letter of intent to form a strategic partnership for the development and commercial operation of a retrofit kit, the first of its kind in the French LCV market.
This innovative solution enables a combustion engine commercial vehicle that is more than 5 years old to be converted to electric power.
The first stage of the partnership, in the form of a “Proof of Concept”, consists of a co-development phase to market a first retrofit kit for retrofit specialist vans before the end of 2023.
The objective of this first stage will be to market and install around 1,000 Retrofit kits and to demonstrate to professional customers the benefits of the retrofit approach (electric driving comfort, respect for the environment, economic gains, etc.).
Eventually, this innovative solution will be extended to other models.
Expert 4WDer and Adventurer Mercedes Lilienthal proves, if it was ever needed, that one can not only travel in an EV, but it can be lots of fun too. Plus what the perfect EV-4×4 looks like. Read her full story here: treadmagazine
If the CA Senate Transportation Committee approves this project, ICE vehicle owners may soon be eligible for a financial rebate if they switch to an electric vehicle’s powertrain.
If AB 2350 passes and becomes law, one would soon be able to receive a financial rebate for swapping one’s drivetrain to EV California. This bipartisan assembly measure, which SEMA is also supporting, aims to persuade individuals to switch to electric vehicles by allowing them to perform a conversion build rather than buying an entirely new car.
California has sponsored initiatives like the Clean Vehicle Rebate Program and the Clean Cars for All Program for years to encourage owners to purchase EVs. The hitch was that these programmes didn’t apply to conversions; they were solely for brand-new cars.
By converting their internal combustion engine (ICE)-powered vehicles to electric vehicles (EVs), owners may be eligible for a $2,000 state reimbursement under Assembly Bill 2350, the Zero-Emission Aftermarket Conversion Project. According to the bill, the Clean Vehicle Rebate Project will have up to $2,000,000 available each year to give applicants rebates for qualified vehicles that have been converted into zero-emission vehicles.