Key Takeaways
- A budget-friendly EV conversion of a 1996 Suzuki Jimny cost under $5,000 and took less than a week.
- The conversion utilized off-the-shelf parts, featuring a 72-volt motor and a lithium-iron-phosphate battery.
- This project reflects a growing trend among enthusiasts converting old vehicles to electric on limited budgets.
Affordable Electric Vehicle Conversion
The electric vehicle (EV) conversion trend is increasingly accessible, allowing car enthusiasts to transform older, non-functional cars without spending a fortune. One standout example comes from YouTuber Life of Troy, who adapted a 1996 Suzuki Jimny, commonly known in the U.S. as the Suzuki Samurai. Faced with repeated engine failures, Troy originally imported the vehicle from Indonesia but decided to convert it to electric after yet another costly repair.
Troy’s conversion was notably straightforward, costing under $5,000 and requiring just five days of labor. His goal was to create a simple, functional vehicle for urban driving—no luxury upgrades involved. The original engine, which generated just 45 horsepower, was removed in favor of a 72-volt direct current motor from D&D Motor. This new motor delivers a modest 9 horsepower but compensates with 65 pound-feet of torque, making it suitable for low-speed driving.
Key components of the conversion included a 500-amp controller priced at $815, and a DC-to-DC converter sourced from eBay. The heart of the system is a 105-amp-hour lithium-iron-phosphate battery initially designed for golf carts. Installed where the gas tank once sat, this battery offers a driving range of approximately 20 to 30 miles on a full charge, significantly enhancing the vehicle’s usability.
Charging the battery is achieved through a standard 120V outlet, taking about five hours to recharge fully. Despite the vehicle lacking a clutch, all gears were retained, simplifying the conversion process. The absence of vacuum-assisted brakes also eliminated the need for additional components like a vacuum pump. The Suzuki can achieve speeds of up to 50 miles per hour, close to its original capabilities.
Troy’s project resonates with a growing community of enthusiasts who have embarked on similar conversions of older vehicles, including ATVs and golf carts. Comments on his videos highlight the accessibility of such projects, encouraging more individuals to undertake their own conversions despite modest budgets.
This movement not only extends the life of aging vehicles but also promotes sustainable transportation options, demonstrating that turning an old car into an electric one is feasible and rewarding for dedicated hobbyists.
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