How Long Does an EV Conversion Take?

Introduction

Converting an internal combustion engine (ICE) vehicle into an electric vehicle (EV) is an exciting project, but one of the most common questions is: How long does it take?

The timeline for an EV conversion varies significantly depending on factors like technical experience, budget, vehicle choice, and project complexity. While some conversions can be completed in a few months, others may take over a year—especially for first-time DIY builders or highly customized builds.

This guide provides a realistic breakdown of the EV conversion process, explaining how long each phase typically takes and what factors can speed up or slow down your project.

How Long Does an EV Conversion Take?

On average, an EV conversion takes anywhere from 3 months to 2 years, depending on whether you choose a DIY approach or a professional shop, the availability of parts, and your level of experience.

Typical Timeframes for EV Conversions

Professional EV Conversion: 3 – 6 months
Basic DIY EV Conversion (Using a Kit): 6 – 12 months
Custom DIY EV Conversion (From Scratch): 12 – 24 months

A professional shop can complete an EV conversion in a matter of months, whereas a DIY conversion often takes a year or more due to the learning curve, part sourcing, and troubleshooting involved.

EV Conversion Timeline – Step-by-Step Breakdown

1. Planning & Research (1 – 3 Months)

Before starting the conversion, you’ll need to choose a donor car that suits your EV conversion goals, decide on an electric motor, battery pack, and power system, research EV conversion kits or custom-built components, and check local regulations to ensure your converted EV will be road legal.

The research phase is crucial, as rushing into the conversion without a clear plan can lead to unexpected delays and costly mistakes.

Time-Saving Tip: Opting for a pre-designed EV conversion kit reduces research time and simplifies the process.

2. Stripping the Donor Car (2 – 4 Weeks)

Once you have your donor vehicle, the first hands-on step is removing the internal combustion engine and unnecessary components, including the engine, exhaust system, radiator, fuel tank, transmission (if switching to a direct-drive electric motor), and cooling and emissions control systems.

This step typically takes a few weeks, depending on the complexity of the vehicle and experience level of the builder.

Time-Saving Tip: Using a lift and engine hoist speeds up removal. A simpler car (e.g., Mazda Miata or Volkswagen Beetle) will be easier to strip than a complex modern vehicle.

3. Installing the Electric Motor & Batteries (1 – 3 Months)

Once the car is stripped, the next step is mounting the electric motor and installing the battery pack. This includes adapting the motor to the existing drivetrain (or replacing the transmission), securing the battery pack and wiring high-voltage connections, and installing a battery management system (BMS) and cooling system.

This step requires precision and expertise, especially if you’re designing the battery mounting system from scratch.

Time-Saving Tip: Buying a bolt-in motor mount and battery box can save weeks of fabrication time.

4. Wiring & Electronics Integration (2 – 6 Months)

This is one of the most time-consuming parts of the conversion, as it involves wiring the battery pack, motor controller, and power distribution system, setting up throttle and regenerative braking controls, integrating dashboard gauges, touchscreen displays, or monitoring systems, and ensuring compatibility with lights, power steering, HVAC, and accessories.

If done incorrectly, poor wiring can cause short circuits, performance issues, or dangerous failures.

Time-Saving Tip: Using a pre-made wiring harness can reduce troubleshooting time significantly.

5. Suspension, Brakes & Chassis Upgrades (1 – 2 Months)

An electric drivetrain changes the weight distribution and handling of the car, so upgrades are often needed for brakes (regenerative braking, upgraded calipers, or disc brake conversions), suspension (reinforced shocks/springs to support battery weight), and tires & wheels (optimized for EV efficiency and traction).

Skipping this step can lead to poor handling or reduced safety.

Time-Saving Tip: If your donor car is already well-balanced, minimal suspension modifications may be needed.

6. Testing, Troubleshooting & Fine-Tuning (2 – 6 Months)

Before hitting the road, the converted EV needs thorough testing and calibration, including checking battery performance and charging efficiency, testing power delivery and acceleration, troubleshooting any software or electrical issues, and optimizing cooling and thermal management.

Testing can take weeks or months, depending on the complexity of the system. Unexpected issues often arise, so patience is essential.

Time-Saving Tip: Keeping the conversion as simple as possible reduces testing time and potential problems.

7. Road Certification & Registration (1 – 3 Months)

Once the EV is complete, it must pass road safety inspections and emissions exemptions (if applicable). This process varies by region and may involve a government or third-party EV inspection, registering the vehicle as an electric car, and obtaining insurance for a custom EV conversion.

Some DIY projects are delayed due to paperwork and approval wait times, so it’s best to research this early in the process.

Time-Saving Tip: Professional conversion shops handle registration and compliance, streamlining this step.

What Factors Affect the EV Conversion Timeline?

Several variables can speed up or delay the conversion process.

Factors That Speed Up the Process

Using an EV conversion kit – Pre-configured kits with motor, batteries, and wiring save months of sourcing and fabrication.
Choosing a simple, lightweight donor car – Vehicles like the Mazda Miata or Volkswagen Beetle are easier to convert than complex modern cars.
Buying pre-made mounting brackets and battery enclosures – Reduces fabrication time.
Having experience in mechanics and electronics – Experienced builders complete projects faster.

Factors That Slow Down the Process

Custom battery design and mounting – Adds complexity compared to a pre-configured battery pack.
Sourcing individual parts instead of a kit – Takes longer due to shipping, testing, and compatibility issues.
Learning curve for first-time builders – DIY builders often take longer due to research and troubleshooting.
Limited workspace or tools – Having the right shop equipment speeds up the process.

Conclusion: How Long Will Your EV Conversion Take?

The time required for an EV conversion depends on your experience level, vehicle complexity, and whether you go DIY or hire a professional.

Professional EV Conversions: Typically 3 – 6 months, offering expertise and faster turnaround.
DIY with a Conversion Kit: Usually 6 – 12 months, depending on technical skills and workspace availability.
Fully Custom DIY EV Conversion: Can take 12 – 24 months, with extensive fabrication and troubleshooting.

Regardless of the timeline, an EV conversion is a rewarding project that results in a unique, eco-friendly, and high-performance electric vehicle. Whether you’re a DIY enthusiast or working with professionals, planning ahead will ensure a smooth and efficient conversion process.

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