Exploring EV Conversion Kits: What Option is Best for You?

As the aftermarket EV industry continues to grow, so do the options for converting traditional gas-powered vehicles into electric ones. With a wide range of kits from various manufacturers, it can be challenging to understand what’s included in each kit and what to expect during installation.

This guide explores the five levels of EV conversion kits available today, from fully DIY solutions to vehicle-specific plug-and-play kits, giving builders of all experience levels a clearer understanding of their options.

Level 0: DIY Source-It-Yourself Solution – The Ultimate Custom Approach

At the most complex end of the spectrum, we find the DIY “source-it-yourself” solution. Builders who choose this route are often taking on the challenge of designing and building a custom EV system, sourcing each component individually and creating a unique Bill of Materials (BOM). This approach appeals to highly experienced builders or enthusiasts who want full control over every detail and are willing to dedicate substantial time to the project. Builders who go this route can also save a good deal of money upfront as they can salvage components from other EVs. 

What It Involves: Builders source and assemble all major components, including the motor, controller, battery packs, and wiring, without the guidance or pre-selected compatibility of a kit. They must have advanced knowledge of EV systems, engineering, and fabrication to ensure the components work together.

Average Time Commitment: 1000+ hours

Cost: $

This DIY approach allows for unparalleled customization – and is often the most affordable option– but demands significant expertise and time. Builders can choose specific components, from high-powered motors and custom battery packs to unique mounting solutions and wiring setups, creating a unique EV that reflects their vision and preferences.

Level 1: Pallet of Parts – Pre-Specced Kits with Room for Customization

A step closer to a structured solution, Level 1 kits provide a “pallet of parts” that offers a pre-specified collection of essential components, such as motors, controllers, battery modules and wiring, which builders then assemble and configure themselves. These kits strike a balance between complete DIY sourcing and a structured kit, making them an attractive option for builders who want guidance on parts but still value a hands-on approach.

What It Involves: Builders receive a pre-packaged set of components that they wire, assemble, and configure themselves. Some fabrication may still be required, particularly with custom mounts, fittings, and connections to adapt the kit to their vehicle.

Example: 

The LEV HyPer9 kit has become a popular choice among DIY builders thanks to its compact and efficient AC motor and controller combination. Known for its reliability and balanced power output, the HyPer9 is suitable for lightweight to medium-weight vehicles. The kit comes with all the major components needed to make the motor spin, but builders are responsible for sourcing and building the battery pack, building wiring harnesses, and mounting components. LEV’s HyPer9 kits provide a middle-ground solution for builders who want a budget friendly and versatile motor setup but don’t need the constraints of a fully engineered, plug-and-play solution.

Average Time Commitment: 500+ hours

Cost: $$

Level 1 kits, like the LEV HyPer9 Kit, allow DIY enthusiasts to make use of high-quality, pre-selected components without limiting the level of customization in the build. These kits appeal to those who want a bit of guidance without sacrificing the freedom of a personalized EV conversion.

Level 2: System Kits – Semi-Custom EV Solutions with Key Subsystems Preassembled

Level 2 kits, commonly referred to as “system kits,” offer a package by including the essential components preassembled necessary for a subsystem in an electric vehicle. These kits might be a full motor system or a pre-packaged battery pack. While the subsystem kits builders must still handle some wiring, some assembly, and often create mounts or adapt the kit to fit their specific vehicle. This approach provides flexibility and reliability without strictly needing to build a battery box or a wiring harness. 

What It Involves: Builders receive a prebuilt subsystem. Assembly of other subsystems and wiring might still be required, and some vehicle-specific modifications are necessary to adapt the kit.

Examples:

ReVolt CR43 Motor Kit: The ReVolt CR43 system kit is a crate motor designed for builders aiming for higher power outputs, making it suitable for high-end performance-focused conversions. With a powerful motor, compatible controller, and wiring harness the CR43 provides ample torque and acceleration. Builders can pair the CR43 with a custom or modular battery pack, allowing for a high degree of flexibility in power capacity and range. This kit is popular among enthusiasts who want a proven powertrain for a high-performance EV without the need to source each individual component required for the motor system.

APP EV Modular Battery Packs: APP EV’s modular battery packs are well-regarded in the industry for their scalability and durability. These packs are designed to integrate seamlessly with many popular motor and control systems, allowing for straightforward installation and versatile configuration options. 

Average Time Commitment: 300+ hours

Cost: $$$

Level 2 system kits offer a convenient balance for experienced builders who want control over their build but appreciate the reliability of pre-engineered subsystems. These kits are ideal for semi-custom projects where builders want to invest in a functional, high-quality EV setup without the full DIY burden.

Level 3: Universal Plug-and-Play Kits – Simplified Installation with Some Flexibility

For those looking to simplify installation without being constrained to any specific donor vehicle, Level 3 kits provide universal plug-and-play options. These kits come pre-engineered with all essential components designed to work together, though they still require some vehicle-specific mounting and fitting. Builders get a streamlined installation with the flexibility to customize the fitment to their chosen vehicle.

What It Involves: These kits include pre-assembled components that reduce wiring and installation time. However, custom mounts or minor adjustments are usually needed to adapt the kit to specific vehicles.

Example:

Ampere EV’s Atom Drive System: Ampere EV’s Atom Drive is a versatile plug-and-play solution that appeals to builders working with a wide range of vehicles. The Atom Drive includes a motor, controller, junction boxes, and a complete battery system, all pre-configured to work together. It comes standard with a custom wire termination service, eliminating the need to build HV or LV harnesses. The Atom Drive System simplifies wiring and control setup, allowing builders to focus primarily on mounting the system into their vehicle.

Average Time Commitment: 150+ hours

Cost: $$$$

Universal plug-and-play kits offer an efficient and reliable solution, allowing builders to save significant time on wiring, engineering, and programming. They’re ideal for those with moderate fabrication skills who want a fast and safe installation with the flexibility to adjust the fitment as needed.

Level 4: Vehicle-Specific Plug-and-Play Kits – Quickest and Easiest Installation

At the simplest end of the spectrum, Level 4 kits provide fully vehicle-specific plug-and-play solutions. These kits are tailored to specific models and come with custom mounts, adapters, and wiring designed to fit the particular vehicle. As the most accessible type of kit, Level 4 solutions allow for straightforward, minimal-effort conversions that can be completed in days.

What It Involves: Complete kits are customized for specific vehicles, including custom mounts and wiring that match the vehicle’s original design. Builders can install these kits with minimal modification or technical skill.

Example:

Fellten’s Vehicle-Specific Kits: Fellten offers a series of vehicle-specific plug-and-play kits for classic European models, such as the Porsche 911 and classic Mini Cooper. Each kit is tailored to fit the original vehicle structure, with pre-designed motor mounts, wiring harnesses, and battery placement configurations. Fellten’s kits are renowned for their ease of installation, high-quality components, and compatibility with iconic classic cars, making them a favorite among collectors.

Average Time Commitment: 40+ hours

Cost: $$$$$

Level 4 vehicle-specific kits make EV conversion accessible to those who prioritize ease and speed of installation. These kits are especially popular among owners of classic or vintage vehicles who want the benefits of electric power without compromising the original aesthetic or requiring extensive modifications to the donor vehicle. By offering pre-engineered, model-specific components, Level 4 kits streamline the entire conversion process, making it feasible to complete a conversion in as little as a few days.

Choosing the Right Kit for Your Project

With options spanning from completely custom to plug-and-play, the five levels of EV conversion kits offer choices to match any builder’s skills, goals, and budget. Here’s a quick guide to help you select the right kit for your needs:

Level 0: DIY Source-It-Yourself – Best for experienced builders on a budget seeking total control and customization, willing to invest extensive time and effort in sourcing and engineering.

Level 1: Pallet of Parts – Suited for DIY enthusiasts who want a structured selection of parts with ample customization, allowing them to design and configure the setup themselves.

Level 2: System Kits – Ideal for builders looking for a reliable, semi-custom solution with prebuilt subsystems, offering the flexibility to adapt the system as needed.

Level 3: Universal Plug-and-Play Kits – Perfect for those seeking a relatively fast installation with minimal engineering but who are comfortable with basic fabrication for mounting and fitting.

Level 4: Vehicle-Specific Plug-and-Play Kits – Designed for beginners or those desiring the simplest, most efficient installation, with all components tailored to a specific model for a quick, straightforward conversion.

The Future of EV Conversion Kits

The EV conversion kit market is set to grow rapidly as demand rises. Manufacturers are expected to release more modular, efficient, and affordable kits, especially as battery technology advances with smaller, more powerful, and cost-effective options, making conversions easier.

This progress will bring new possibilities for both DIY enthusiasts and professionals, including hybrid kits that balance customization with ease, and “smart kits” with built-in diagnostics for simpler maintenance. Converting a vehicle to electric will soon be an appealing option for anyone wanting to modernize their car.

Whether you’re new to EVs or an experienced builder, the range of available kits means there’s a solution for everyone. By understanding the five kit levels, you can choose one that fits your skills and goals, making your shift to electric both satisfying and enjoyable.

Ready to get started on your own EV project?