Little Project, Big Time Deal

At Legacy EV, we love pushing the boundaries of what’s possible in the world of EV conversions and education. From high-horsepower classics to cutting-edge curriculum, we’ve worked on some exciting projects—but sometimes, the most unassuming builds make the biggest impact. That’s exactly the case with our latest project, a 1997 Subaru Sambar Super Deluxe Kei truck that we’re converting to electric in partnership with the Big Time YouTube channel.

What makes this build unique isn’t just the size of the vehicle—it’s how we’re doing it. Instead of starting with a brand-new EV powertrain, we’re repurposing components from one of our decommissioned training benches, giving second life to EV parts while showcasing how sustainability and accessibility can go hand in hand. This project is more than just a fun build; it’s a demonstration of how practical and affordable EV conversions can be when approached with creativity and engineering ingenuity.

The project started in a way only Big Time could pull off. The team personally delivered the Sambar to our shop in their 1977 Kenworth K100 Cabover, making an unforgettable entrance with their massive hauler. After parking their vintage rig, they spent the day touring our facility, meeting the team, and getting a firsthand look at how we develop EV conversion technology. We talked shop, swapped ideas, and wasted no time getting started on the teardown of the Sambar’s factory powertrain. Their enthusiasm for learning was evident, which is why they’ll be coming back soon for our EV Fundamentals Bootcamp, where they’ll gain hands-on experience working with high-voltage systems, battery management, and powertrain integration.

With the truck in our hands, we got straight to work. Now, just a few weeks in, we’ve made significant progress toward transforming this tiny, gas-powered workhorse into a torquey, emissions-free EV.

Why the Subaru Sambar?

Kei trucks like the Subaru Sambar Super Deluxe have been a staple of Japanese roads for decades. Designed for tight urban environments and light utility work, these trucks are known for their compact size, lightweight construction, and surprising durability. More recently, they’ve gained popularity in the U.S. enthusiast scene, offering an affordable and quirky alternative to full-size pickups.

The 1997 Subaru Sambar Super Deluxe we’re working with originally came with a 658cc EN07 carbureted engine, producing 39 horsepower and 39 lb-ft of torque. It featured a 5-speed manual transmission, rear-engine layout, switchable 4WD, and a cargo capacity of 771 pounds. While efficient in its stock form, it was built for practicality rather than performance. That’s about to change. With a Hyper9 electric motor delivering 120 hp and 162 lb-ft of torque, we’re giving this truck over three times its original power output and a massive boost in torque, all while making it significantly cleaner and more efficient.

Repurposing EV Components: A Sustainable Approach

At Legacy EV, we don’t just teach people how to build EVs—we live by our own lessons. When one of our training benches was retired from active duty, we saw an opportunity. Instead of letting perfectly functional components go to waste, we decided to repurpose them for this real-world conversion.

This approach is more than just environmentally responsible—it’s a proof of concept that EV conversions can be made more cost-effective and accessible without always requiring brand-new parts. By integrating previously used EV components, we’re demonstrating that high-quality, second-life EV parts can still deliver top-tier performance in a conversion.

Build Progress: From Gas to Electric

With the gas-powered drivetrain removed, we immediately set to work modifying the Sambar to handle its new electric heart. Since this vehicle wasn’t originally designed for an EV swap, every step required engineering and fabrication to ensure everything fit and functioned properly.

To accommodate the new powertrain, we reinforced the frame to support the added weight of the battery pack and increased torque output. One of the biggest structural modifications involved repurposing the front differential and mounting in the rear, allowing us to install a driveline connected to a 1.9:1 torque box and the Hyper9 motor. We also fabricated and installed a custom crossmember to properly secure the torque box, ensuring the entire drivetrain remains stable under load.

Mounting the supporting components was another key focus. We fabricated a mounting plate to secure the TSM2500 3kW charger, 1000W DC-DC converter, and other critical electronics. These components will be housed in the same compartment under the truck bed where the original engine once sat, ensuring accessibility and efficient use of space. For power management, we mounted the inverter under the passenger floor, using nutserts instead of bolts to simplify serviceability in the future. For a clean, factory-like integration, we routed the charge port to the truck’s original fuel filler location.

To ensure the truck remains usable in all weather conditions, we modified the original heater box to fit an HV heater core. Instead of designing a completely new heating system, we adapted the stock heater box, cutting a slot for the HV heater core to slide into the existing mounting points. This allows us to retain the original airflow design while upgrading the heating system for electric operation. 

The heart of this conversion is the battery system, which is now taking shape. Before physically installing anything, we designed the battery pack layout in CAD and used a full-size paper mockup for wire routing, before the aluminum box pieces arrived from Send Cut Send. The final design places a 32.9kWh battery pack beneath the truck bed, consisting of 14 Kore Power modules arranged in an alternating PN/NP configuration for optimal busbar placement. Managing the 175V system is a Dilithium Designs BMS, ensuring proper voltage monitoring, thermal management, and system protection. Wiring the BMS cell taps was a tedious but necessary process, requiring precise splicing, insulation, and routing to accurately monitor the voltage of each battery module.

Building the Future of EV Education

This project isn’t just about building an electric Kei truck—it’s also shaping the future of EV education. Every challenge we solve and every design decision we make is being documented and integrated into Legacy EV’s EV Build Fundamentals curriculum.

Instead of learning purely from theory, students will get real-world case studies based on this build, covering engineering challenges, troubleshooting techniques, and best practices for EV conversions. When the Big Time crew returns for our EV Fundamentals Bootcamp, they’ll get a firsthand look at our approach to EV education including battery management, high-voltage system safety, and powertrain integration, furthering their understanding of EV systems.

Why This Project Matters

This build is more than just a cool conversion—it represents a shift in how we think about EV swaps, sustainability, and education. It’s a case study in how EV conversions can be:

What’s Next?

With the battery pack nearing completion and the drivetrain fully installed, we’re getting closer to powering up this tiny beast for the first time. The next steps include finalizing wiring, high-voltage safety testing, and performance tuning.

Be sure to follow along for more updates in Amped Up, and watch the full build unfold on Legacy EV's and Big Time’s YouTube channel. If you’re thinking about starting your own EV conversion—whether it’s a Kei truck, a classic car, or something entirely different—Legacy EV has the parts, training, and expertise to make it happen.