Racing Against Time: Electrifying 100 Year Old Film Cars

In August of 2022, we received a call from a movie production company with an unprecedented request: they needed eight vintage vehicles from the 1920s electrified for an upcoming historical series. 

The catch?

These cars had to retain their period-correct appearance while offering modern reliability and efficiency. The tight filming schedule demanded that we deliver eight complete conversion kits within just three weeks—the largest single kit order Legacy EV had ever received at that time.

Why Did a Film Set Need EV Conversions?

Cars from the 1920s are notoriously difficult to operate, especially in freezing temperatures. Even skilled mechanics struggle to start them reliably, let alone actors and extras who would be required to drive them during filming. The production team needed a solution that would allow these vintage vehicles to function effortlessly on cue, without requiring an on-set team of mechanics to coax them into operation before every take. Seamless running of show cars is essential to keeping everything on schedule and under budget.

Additionally, the roar of combustion engines from that era presented a major challenge for audio engineering. Period-correct scenes required capturing dialogue and ambient sound without interference, something nearly impossible with the chugging and sputtering of nearly century-old gasoline engines. By converting these vehicles to electric, the production team ensured clean, reliable performance and eliminated one of the biggest hurdles in capturing high-quality sound.

Balancing Authenticity with Modern Technology

The challenge was clear: integrate state-of-the-art electric components into nearly century-old vehicles without compromising their classic aesthetics. So we embarked on converting eight unique vehicles, including two Ford flatbed trucks, a Model T Coupe, a GMC truck, a Buick sedan, and a Maxwell. 

For this project, speed, range, and high performance were not priorities. Instead, the focus was on reliability and a fast turnaround time to meet the tight filming schedule. To achieve this, we selected industry-standard components that would integrate seamlessly into the variety of vintage vehicles.

• Motors: We chose HyPer9 motors, known for their dependability and ease of integration. These were mated to TorqueBoxes, which allowed us to avoid adapting to the diverse range of transmissions already equipped in these classic vehicles.
• Batteries: Tesla battery modules were the preferred choice, providing proven reliability and compact packaging.
• Chargers: TSM2500 onboard chargers were selected for keeping the HV batteries topped off, while Elcon DC-DC converters ensured the 12V batteries stayed charged.

Each vehicle presented its own set of challenges, from accommodating the size and weight of modern batteries to ensuring that the new components didn’t alter the vehicles' iconic looks. Since every vehicle was different, they all required a different set of custom mounts and battery boxes. Additionally, most of the vehicles to be converted had a singular brake on the driveline, which needed to be replicated with modern components by adding a disc brake on the new drivelines just after the torque box.

Filming conditions added another layer of complexity. The vehicles needed to perform reliably in various environments, including cold weather. We focused on ensuring that the electric drivetrains were robust and that the battery systems were insulated and efficient enough to handle temperature variations. These optimizations meant that the vehicles started instantly, every time, no matter the conditions.

A Looming Deadline

The three-week deadline loomed large, and the stakes were even higher than we initially realized. The picture car coordinator confided in us that if this plan didn’t work out, he was liable to lose his job. The shooting schedule had already been set before the parts were ordered, adding even more pressure to deliver on time.

To meet this immense challenge, the Legacy EV team worked closely with vendors to ensure that all necessary components were sourced, tested, and shipped as quickly as possible. Our suppliers and internal teams put in overtime, expediting orders and coordinating shipments to keep everything on track. Legacy EV also enlisted the help of one of their premier authorized installers, Conductive Classics, as the film crew was going to need in-person expertise to hit their ambitious goal.

The first set of kits was sent out within the week, allowing the Picture Cars team to begin work on-site. Shortly after, a second shipment followed to ensure that all the remaining vehicles had the parts necessary for conversion.

Conductive Classics then arrived on set, working closely with the Picture Cars team to finalize the first few builds before tackling the remaining five vehicles. Over an intense seven-day stretch, the Conductive Classics team completed the full conversions for these remaining cars, ensuring that each vehicle was operational and ready for filming.

As soon as a car was finished, it was immediately sent to the set, keeping production on schedule. The collaborative efforts between Conductive Classics, Picture Cars, and Legacy EV’s remote support team ensured a seamless integration of electric drivetrains into these historic vehicles.

A Successful Premiere with A Broader Impact

The hard work paid off. The electrified vehicles performed flawlessly during the first season’s filming. They provided the production team with authentic-looking, quiet, and emission-free cars that enhanced the show’s historical accuracy without the unpredictability of 100-year-old combustion engines.

Beyond seamless and quiet operation, EV conversions are used in other unique film cases. For example, for an automotive chase scene through a casino, it would be necessary to ensure that the vehicle doesn’t emit fumes. In other cases, like filming in a gas plant or oil refinery, internal combustion engines are often not allowed due to safety concerns.

This project wasn’t just a win for us; it highlighted a growing trend in the film industry. As streaming platforms and audiences demand higher-quality productions, there’s an increasing emphasis on sustainability and efficiency. Electrifying classic vehicles offers a practical solution, allowing filmmakers to use genuine vintage cars without the environmental and reliability concerns associated with older engines.

Reflecting on the Journey

Looking back, this project was a testament to what’s possible when innovation meets dedication. We took on a challenge that required us to push our boundaries, collaborate effectively, and deliver excellence under pressure. The successful electrification of these vintage vehicles not only met the needs of our client but also set a precedent for future projects in the film industry and beyond.

As the entertainment industry continues to evolve, the integration of electric vehicles—both in front of and behind the camera—will undoubtedly play a significant role in shaping sustainable and efficient production practices.