EV Conversion Costs
Converting a classic metal scooter to an EV is not a turnkey operation (at least yet, although that may change in the future). Kits are available that can make the conversion easier, and they really aren’t that expensive considering the amount of work, experimentation and false starts involved with a conversion from scratch.
But you probably wouldn’t be reading this if you weren’t seriously considering the challenge and satisfaction!
Here’s a list of what you will need to make yourself, and what you can buy and the approximate costs.
| What you’ll need to make (or have someone else make): | |||
|---|---|---|---|
| Component | Materials | Cost | Notes*** |
| Swingarm | Steel or aluminum | $50-$300 | If you send it to a cutting service (for example, sendcutsend.com) expect to pay $50 per component, but you will still need to weld. Totally outsourcing to a fabricator will cost several hundred dollars |
| Component container | Marine plywood or metal mounting brackets | $100 | A pre-built pack may come in a case. Otherwise, I’d allocate $100 (placeholder) |
| Other brackets and mounting | Steel | $50 | To mount battery and components, $50 (placeholder) |
| Wiring and connectors | Copper, tinned copper | $150 | You will need to crimp the big wires and solder others. Basic crimpers are about $50 on Amazon, expect to pay $100 for wire and connectors. |
| What you’ll need to purchase (72v system): | ||
|---|---|---|
| Component | Cost | Cost /notes |
| Battery Pack | $1,060 | This can vary widely based on your needs (use this as a placeholder for a 35 miles range pack). |
| Motor* | $315 | For a QS Motor 4kw hub motor |
| Controller* | $207 | For a Fardriver |
| Disk Brake* | $30 | From the QS Motor website |
| Tire* | $50 | From the QS Motor website |
| Rear brake master cylinder | $30 | From Amazon |
| Key switch | $25 | From Thunderstruck Motors |
| DC to DC converter | $115 | From Thunderstruck Motors |
| Contactor | $150 | From Thunderstruck Motors |
| Fuses | $50 | From Thunderstruck Motors |
| Shipping from China | $300 | Usually DHL or Fedex |
| Contingency | $350 | There’s always stuff that you didn’t expect! |
| Total for parts made and purchased (not including design) | $2932-$3182 | (US Dollars) |
Expect to spend $2,900 to $3,200 USD on converting your scooter to an EV.
What About Designing the EV and Electrical System?
If you’ve modified a scooter or car, the skills are directly applicable and will be useful in designing an EV Scooter. However, you may need to acquire electrical design skills through self study or making new friends. The voltage in a 72v system can be lethal, so don’t underestimate this area.