The 1958 Chevrolet Apache is a timeless classic, but this restomod takes it to a whole new level—combining vintage aesthetics with cutting-edge Tesla electric power. This Tesla swapped Chevy Apache is more than just an EV conversion; it’s a high-performnce, sustainable build that retains its old-school charm while delivering modern power and efficiency.
Why Tesla Swap a 1958 Chevy Apache?
Swapping out a traditional gasoline engine for a Tesla powertrain provides several benefits:
⚡ Instant Torque & Smooth Acceleration – Experience electric performance with unmatched responsiveness.
🌱 Eco-Friendly & Zero Emissions – Reduce your carbon footprint without sacrificing power.
🔧 Less Maintenance – Say goodbye to oil changes and exhaust system repairs.
🚀 Enhanced Performance – More horsepower and better handling with modern upgrades.
This EV restomod build isn’t just about sustainability—it’s about pushing the limits of automotive engineering.
The Tesla Powertrain & Battery Setup
This 1958 Chevy Apache EV conversion is powered by a Tesla-sourced drivetrain, ensuring a thrilling and efficient ride.
🔋 Key Components of the Tesla Swap:
Motor: Tesla Model S rear drive unit
Battery Pack: 48kWh battery sourced from a Chrysler Pacifica hybrid
Charging System: Level 2 charger integration for fast and convenient charging
Range: Estimated 150-200 miles per charge
Modern Performance Upgrades
To complement the electric powertrain, the build incorporates several suspension and braking upgrades:
Front Suspension: 2nd Gen Chevrolet Camaro front clip for improved handling
Rear Suspension: Independent rear suspension from a Cadillac for a smoother ride
Brakes: High-performance disc brakes for enhanced stopping power
Custom Wheels & Tires: Performance-grade rubber for optimal traction
This combination ensures that the Tesla-swapped Chevy Apache retains its vintage appeal while offering modern-day drivability.
How It Drives: Classic Meets Future
Driving this electric 1958 Chevy Apache is a completely different experience from its gasoline-powered counterpart. The instant torque from the Tesla motor delivers seamless acceleration, making city driving and highway cruising equally exhilarating. With its upgraded suspension, the truck handles corners with confidence while maintaining the comfort of a classic ride.
🚗 Driving Experience Highlights:
0-60 MPH: Estimated in under 5 seconds
Silent yet Powerful: No engine noise, just raw electric acceleration
Improved Handling: Lower center of gravity for better stability
Regenerative Braking: Extends battery life while reducing brake wear
Challenges & Lessons from the Tesla Swap
Building an EV restomod isn’t without its challenges. Here are some hurdles faced during this Chevy Apache Tesla swap:
Battery Placement & Weight Distribution – Strategic mounting to optimize balance
Integration with Classic Electronics – Converting analog systems to work with digital EV components
Cooling System Adjustments – Keeping the battery and motor temperature in check
These challenges were met with innovative solutions, making the Tesla swapped Chevy Apache a seamless blend of old and new.
Tesla Swap Cost Breakdown
A project like this requires time, money, and expertise. Here’s a rough cost estimate:
Component
Estimated Cost
Tesla Motor & Inverter
$10,000 – $15,000
Battery Pack
$5,000 – $8,000
Suspension Upgrades
$3,000 – $5,000
Brakes & Wheels
$2,500 – $4,000
Labor & Custom Fabrication
$10,000+
Total Estimated Cost
$30,000 – $50,000
Is an EV Restomod Worth It?
For those passionate about classic trucks but eager for modern performance and sustainability, a Tesla-swapped Chevy Apache is the perfect solution. This build not only preserves the timeless charm of a 1958 Chevrolet Apache, but it also delivers the efficiency and power of the Tesla electric drivetrain.
Final Thoughts
This EV restomod conversion proves that classic vehicles can embrace the future without losing their identity. Whether you’re a classic car enthusiast, an EV advocate, or someone simply looking for an exciting build, this Tesla-swapped Chevy Apache is an inspiring example of what’s possible.
🔋 Want to build your own Tesla-swapped classic? Stay tuned for more in-depth guides and conversion tips!
The 1966 Ford Mustang is the kind of car that turns heads no matter where it rolls. It’s an icon—pure muscle and attitude wrapped in a sleek fastback silhouette. But what if you could ditch the carburetor, lose the oil leaks, and still keep the soul of a proper hot rod? That’s exactly what this electrified pony does. With a custom-built EV powertrain under the hood, this Mustang blends vintage style with modern punch, delivering instant torque and zero-emissions burnout potential.
From Gas Guzzler to Green Machine
Let’s be real—classic muscle cars are a riot to drive, but they can be a nightmare when it comes to maintenance. Tuning a carb, chasing oil leaks, and fighting with temperamental old-school transmissions are all part of the deal. But with this build, all that’s in the past. Gone is the thirsty V8, replaced with a twin-motor setup that packs a serious punch. No more worrying about cold starts or overheating—just raw, electric power at your disposal anytime you drop the hammer.
The Heart of the Transformation
Forget what you think you know about EV swaps—this isn’t just some golf cart powertrain slapped into a classic body. This ’66 Mustang is running dual NetGain Hyper9 HV 144V motors, managed by twin HyPer-Drive X144 controllers. That means a combined 240 horsepower and 324 lb-ft of instant, tire-shredding torque. And unlike most EV conversions, this one keeps the fun factor alive with a 3-speed manual transmission. That’s right—grab a gear and launch it like you would any other proper hot rod.
Keeping the Spirit Alive
The best part? It still looks and feels like a real-deal Mustang. The exterior is all classic, from the chrome bumpers to the aggressive stance. Inside, the original gauges have been repurposed with SpeedHut EV dials, blending nostalgia with modern function. Even the soundtrack hasn’t been forgotten—a USA-740 Bluetooth radio pumps tunes through a JBL amp and coaxial speakers, because what’s a muscle car without some road trip rock blasting through the cabin?
Power That Hits Hard
This isn’t some underwhelming EV swap—it’s a proper performance build. With Tesla Model S battery modules split into two packs (15.6kWh up front and 36.4kWh in the rear), it delivers a total of 52kWh, giving it an estimated 150-mile range. The Elcon UHF 6.6kW charger keeps things topped up, while regenerative braking helps put some juice back in the pack every time you lift off the throttle.
Built to Handle
Throwing down electric power is one thing—handling it is another. That’s why this Mustang got a full chassis and suspension overhaul. Up front, it rides on a Mustang II setup, while out back, a beefed-up Ford Explorer 8.8-inch axle keeps everything in check. Stopping power comes from four-wheel disc brakes with regenerative braking, making sure this thing can scrub speed as well as it can build it.
Staying Cool Under Pressure
EVs generate heat, and this build has cooling dialed in. A dual Derale Performance cooling kit keeps the motors and battery packs at optimal temps, ensuring that this Mustang is ready to rip at any moment. And since no classic cruiser is complete without A/C, a Vintage Air system keeps the cabin chill, even when you’re lighting up the tires in the summer heat.
1966 Mustang EV Build Specs
Powertrain
Specification
Details
Motors
Dual NetGain Hyper9 HV 144V
Inverters
2 HyPer-Drive X144 controllers
Power Output
240 HP (179kW) combined
Torque
324 lb-ft (439Nm)
Transmission
3-speed manual
Drive Type
Rear-wheel drive
Battery System
Specification
Details
Configuration
10 Tesla Model S battery modules in two packs
Front Pack
15.6kWh
Rear Pack
36.4kWh
Total Capacity
52kWh
Estimated Range
~150 miles
Charger
Elcon UHF 6.6kW w/ CANbus
Chassis and Suspension
Specification
Details
Front Suspension
Mustang II setup
Rear Axle
Modified Ford Explorer 8.8-inch
Brakes
Four-wheel disc with regenerative braking
Cooling and Comfort
Specification
Details
Cooling System
Dual Derale Performance cooling kits for motor and batteries
Air Conditioning
Vintage Air system
Interior Features
Specification
Details
Instrumentation
Repurposed SpeedHut EV gauges
Audio
USA-740 Bluetooth radio, JBL amplifier, coaxial front and rear speakers
A New Era for the Pony Car
This Mustang is proof that the future of hot rodding doesn’t mean losing the past. It’s still a fire-breathing, tire-shredding machine—just without the fire. By blending classic style with cutting-edge EV tech, this build keeps the spirit of the original alive while embracing the next generation of performance. Whether you’re a die-hard muscle car fanatic or an EV enthusiast, one thing’s for sure—this Mustang is built to thrill.
In the heart of Scottsdale, Arizona, a 1947 Ford COE (Cab Over Engine) has received an electrifying transformation that marries vintage charm with groundbreaking technology. This project dubbed the COEV, is the brainchild of Dennis and Beth Kilpatrick, and it redefines what’s possible for the classic vehicle world. With a blend of surgical precision and eccentric creativity, the COEV turns heads and sets a new standard for electric conversions.
A Vision Brought to Life
This wasn’t just a simple build—it was an artistic experiment. Over 1,000 hours of meticulous work by Mark Scalpone and his team at Vintage Iron and Restoration breathed new life into this Ford COE. Every detail was meticulously crafted, from the chassis to the electrics, with touches that reflect Dennis’s profession as an eye surgeon. A playful yet functional theme emerged, with “surgical stitches” visible on the cab and surgical tools cleverly integrated into the build. But the real magic happens under the hood—well, the flatbed, technically.
Power That Defies Expectations
Strap in, because the power under the COEV’s flatbed is truly next-level. The truck’s electric heart comes in the form of a ReVolt CR-43 crate motor, pushing out a staggering 603 horsepower and 800 lb-ft of torque. This powerhouse motor, mounted like a showpiece, feeds power through a Casale billet V-drive and into a Strange solid rear axle. What’s the result? A 0-60 mph time of 5.9 seconds, all while tipping the scales at 4,575 pounds. This is no ordinary truck—this is an electrified monster built to perform.
Innovative Battery Tech and Range
At the core of the COEV’s power system lies a 100 kWh battery pack built from sixteen Tesla Model S modules. These batteries are housed in an AmpRevolt modular battery box, strategically placed to optimize weight distribution. Thanks to this smart design, the truck boasts a range of over 200 miles, an impressive feat for a vehicle of this size and style.
Chassis and Suspension: Crafting Comfort and Control
The COEV’s chassis was custom-built, starting with a shortened 2000 Ford F-150 frame. A Ridetech 4-link rear suspension and Aldan American coilovers ensure a smooth and controlled ride, while the front end features Mustang II control arms and spindles. This setup provides the perfect balance of comfort and performance, essential for the daily drive or an evening cruise. It rides on 15×8 Wheel Vintique wheels, wrapped in Nexen Redline tires, bringing a vintage touch while maintaining modern traction.
Interior: Functional and Stylish
Step inside, and you’re greeted by a surprisingly spacious and comfortable cab. Despite the cab-over design, there’s plenty of room, and the modern updates ensure comfort for long rides. A rear bench from a 2019 Ford Ranger provides seating, while the custom-painted dash and Dakota Digital gauges tie everything together. An iPad Mini serves as the infotainment system, complete with Pioneer speakers and JL Audio amplifiers, offering an audio experience that matches the truck’s performance.
Exterior: Classic Rat Rod, Modern Twist
The COEV’s exterior retains a rat-rod aesthetic that’s both weathered and charming. The 4-inch chop, custom flatbed, and fabricated visor give it an aggressive, yet refined look. Upgraded LED halo headlights and repurposed 1957 Thunderbird taillights add a modern touch without losing the truck’s classic roots. The “electric fence” surrounding the motor is made from a combination of vintage items like fishing rods and camshafts, further emphasizing the truck’s unique character.
The Vision of Vintage Iron and Restoration
Founded in 2004, Vintage Iron and Restoration has built a reputation for exceptional craftsmanship and innovation. With a focus on restoring American icons, the shop has also embraced the challenge of electric vehicle conversions. Their journey into electrification began with a 1972 El Camino and has now culminated in the COEV, a perfect fusion of classic car styling and modern technology. Mark Scalpone and his team continue to push the envelope, demonstrating that even the quirkiest builds can be reimagined with cutting-edge EV technology.
Final Thoughts: A Masterpiece on Wheels
The COEV is more than just a custom build—it’s an electric revolution on wheels. Combining vintage Ford styling with modern electric power, this truck is a true one-of-a-kind creation. Its quirky design and unparalleled craftsmanship make it stand out as not just a showstopper, but a statement piece that’s bound to turn heads wherever it goes.
This Chargezilla Tesla Swapped F100 “Old to Bold” episode shows precisely what it takes to convert an old, tired Ford truck into a Tesla battery-powered machine. Here you will see what components we are using and how we place them into the 1965 Ford F-100 / F-250 chassis.
The episode begins at 101 Motors headquarters in Mesa, Arizona. The team starts to strip the old truck down to its rolling chassis. The bed is first to be removed. The cab and front clip are next. The steering column puts up a fight, but the body is soon lifted off. The old straight-six gasoline engine and the manual transmission are removed. The frame is largely in a good condition with surface rust. The old shocks are pretty much shot.
Legacy EV is a company that provides EV-swap conversion kits, EV-swap advice, as well as education and training to make such a build possible. The LegacyEV team selected and provided all of the components for the Chargezilla build.
The Motors
The power comes from dual NetGain Hyper-9 electric motors. Each motor weighs just under 150 pounds and provides about 130 hp and 173 lb-ft of torque. Each motor is currently listed at $5,150 for a total of $10,300.
The Pack
Chargezilla is using 15 Tesla battery modules for a total battery capacity of 78 kWh. Each module weighs about 58 lbs and costs $1,350. This means the entire battery system weighs about 870 lbs and costs $20,925.
Charger
The truck is using two Thunderstruck Motors onboard charger modules for a total of 6 kW of charging capability. The total cost of the chargers is $1,110.
Transmission/Transfer Case
We need to multiply the torque before we send it to the 4×4/4Lo transfer case and to the truck’s axles. We are using a Torque Trends EV-TorqueBox with ParkLock. The cost of this component is $3,795.
Once you include the inverter, converter, controllers, and battery management system – the cost of all of the premium components for this build is around $40,000.
The teams at LegacyEV and 101Motor built a motor cradle that houses both Hyper-9 motors and the TorqueBox. These will be mounted in the space occupied by the old 4-speed manual transmission. The output shaft of the TorqueBox goes directly into the native “divorced” transfer case. All downstream driveshafts and axles are reused.
Chassis
The frame was cleaned and painted. The rear part of the frame was modified and reinforced to house a battery box that houses five Tesla modules. This box is mounted where a spare tire would have been mounted. The second battery box that houses 10 Tesla modules is mounted under the hood. The battery coolant radiator and coolant lines are routed to both battery boxes.
The body and bed are mounted back on top of the frame for a stealth look. From 10 feet away, nobody will be able to tell that this 1965 Ford truck is electric. The charger port is mounted where the original fuel cap and filler were.
Wrap it Up
The Chargezilla Tesla Swapped F100 “Old to Bold” episode demonstrates the process of converting a classic Ford truck into a modern, electric vehicle. By stripping the truck down to its rolling chassis, the team at 101 Motors and LegacyEV were able to install state-of-the-art components, including dual NetGain Hyper-9 electric motors, 15 Tesla battery modules, and Thunderstruck Motors onboard charger modules. With a total cost of around $40,000 for all premium components, the Chargezilla build showcases the possibilities of EV-swap conversions and the potential for older vehicles to be given new life as electric cars. The finished product is a sleek and powerful electric truck, that looks like a classic Ford truck but has the power and capability of a modern electric vehicle.
The rapid growth of electric vehicles (EVs) has revolutionized the automotive industry, driving innovations in motor technology to improve efficiency and performance. Two primary types of motors used in electric cars are alternating current (AC) motors and direct current (DC) motors. Each type has its advantages and drawbacks, making them suitable for different applications in the realm of electric mobility.
Swapping an internal combustion engine for an electric motor is the future of custom car builds, but one big question stands in the way: How do you choose the right motor for your EV conversion? Whether you’re building a weekend cruiser, a daily driver, or a high-performance track monster, selecting between an AC or DC motor is a critical decision. AC motors offer efficiency, regenerative braking, and OEM-level reliability, while DC motors deliver simplicity, raw torque, and a classic DIY-friendly setup. But which one is best for your build? Let’s break down the key differences and help you decide which motor is right for your electric conversion.
AC Motors:
AC motors are the more commonly used option in modern electric vehicles. One of their key benefits is their simplicity in design and construction, which translates to reduced maintenance requirements and higher reliability. Additionally, AC motors offer a high torque-to-weight ratio, making them suitable for acceleration and maintaining speed even on inclines.
One significant advantage of AC motors is regenerative braking. During deceleration or braking, AC motors can reverse their role and function as generators, converting kinetic energy back into electrical energy to recharge the battery. This regenerative braking system improves overall efficiency and extends the vehicle’s range.
DC Motors:
Direct current (DC) motors were more commonly used in the early days of electric cars but have largely been surpassed by AC motors in modern designs. However, DC motors still find application in specific niche markets due to their simplicity and cost-effectiveness.
One of the main drawbacks of DC motors is that they require more maintenance than AC motors, primarily due to the presence of brushes and commutators, which wear down over time. This leads to reduced efficiency and a shorter lifespan compared to AC motors.
Comparison:
Efficiency: AC motors generally have higher efficiency than DC motors, resulting in better range and longer battery life. The absence of brushes and commutators in AC motors reduces friction and wear, enhancing overall performance.
Regenerative Braking: AC motors outperform DC motors in regenerative braking capabilities, efficiently recovering energy during braking and deceleration. This feature significantly contributes to the extended range of electric vehicles using AC motors.
Cost and Maintenance: DC motors are more affordable to manufacture and maintain due to their simpler construction. However, the overall efficiency and performance gains provided by AC motors often outweigh the cost difference.
Torque and Acceleration: AC motors tend to provide higher torque at low speeds, making them ideal for quick acceleration and better handling in stop-and-go traffic conditions.
Top Electric Vehicles and Their Motor Types:
Several electric vehicles have made a significant impact on the market. However, it’s important to note that new models may have been introduced since then, so the following list may not be exhaustive. Here are some prominent EVs and their motor types:
Tesla Model S and Model 3: Both Tesla’s Model S and Model 3 use AC induction motors. Tesla, being one of the pioneering companies in the EV market, has heavily favored AC motors due to their efficiency and regenerative braking capabilities.
Nissan Leaf: The Nissan Leaf utilizes an AC synchronous motor. Like Tesla, Nissan recognizes the advantages of AC motors for everyday driving and urban commutes.
Chevrolet Bolt EV: The Chevrolet Bolt EV is equipped with an AC synchronous motor, which contributes to its peppy acceleration and commendable range.
BMW i3: BMW’s i3 is fitted with an AC synchronous electric motor, optimized for city driving and navigating congested streets.
Audi e-tron: Audi’s e-tron SUV features AC induction motors, combining power and efficiency to deliver a dynamic driving experience.
Hyundai Kona Electric: The Hyundai Kona Electric is equipped with a permanent-magnet synchronous motor, offering a good balance of performance and efficiency.
Jaguar I-PACE: Jaguar’s I-PACE utilizes AC synchronous motors, showcasing the brand’s commitment to embracing advanced electric propulsion technology.
In conclusion, while both AC and DC motors have their merits, AC motors have emerged as the preferred choice for modern electric vehicles due to their higher efficiency, regenerative braking capabilities, and overall better performance. As EV technology continues to advance, we may witness further refinements in motor technology, leading to even more efficient and sustainable electric mobility solutions in the future.
Want all of the power and more of a mega cubic inch, turbo, or supercharged motor with the reliability of a modern sedan?
The answer may be to install a Tesla drivetrain or similar electric crate motor setup. But it can be an undertaking that will require fabrication, advanced electrical knowledge, and a big budget. The result will be 600-800 horsepower of reliable, rechargeable chaos that will behave like a docile commuter when needed. The Tesla Swap Complete guide below will help you decide if you are up for the challenge to Tesla Swap your Car.
What is a Tesla Swap?
A Tesla swap, at its core, is the process of replacing a vehicle’s traditional internal combustion engine (ICE) with a Tesla electric motor and battery system. This transformation turns a gas-powered car into a fully electric vehicle (EV), delivering the unparalleled performance, efficiency, and eco-friendliness Tesla is known for. But it’s not just about the mechanics—it’s about redefining what’s possible in automotive innovation.
Tesla swaps are gaining momentum among car enthusiasts for their ability to merge cutting-edge EV technology with the timeless appeal of classic cars, hot rods, and even off-road rigs. Imagine the blistering acceleration of Tesla’s electric power paired with the vintage charm of a 1960s muscle car or the rugged durability of a 4×4. It’s the ultimate marriage of old-school aesthetics and futuristic engineering.
At Kaizen Motoring, we believe in continuous improvement, which is why this guide dives deep into the Tesla swap process. From selecting the right donor car and motor to tackling wiring and cooling challenges, we’ve got you covered. Whether you’re curious or ready to electrify your ride, this guide will help you understand the journey ahead. Welcome to the future of custom
Complete Tesla Model S drive unit for sale as a complete drop-in package. This unit will run up to 400 Volts and 400 kW, delivering more power at an affordable price than many of the other packages available. This kit includes the Tesla motor, inverter, gearbox, control unit (EV Controls), throttle pedal, throttle pedal plug and pins, brake switch, brake switch wiring plug and pins, encoder plug, and pins, inverter plug and pins, axle clips, 2 axles, pre-charge relay, and pre-charge resistor.
The Stealth EV Tesla Drive Units handle the pre-charge system and main contactors directly from the internal control board (no external vehicle control unit required). The throttle pedal and brake pressure transducer link directly to the drive unit with NO CAN input required.
Motor from a Tesla, an inline gear reduction where a traditional transmission would bolt up behind an engine, and a universal joint waiting to be fixed to a driveshaft.
Battery Options – Cells – Packs – Enclosures
Battery with BMS -A suitable high-voltage battery will likely be the single largest expense of the build. It needs to be sized properly both in total energy capacity as well as instantaneous current capability to support the power you want to make.
How big a battery do I needfor my EV Swap? Here are some very rough estimates for how many miles you can expect to travel for each usable kw/h of capacity your battery has.
Economy driving = 3.2 mi/kWh
Normal driving = 3 mi/kWh
Spirited driving = 2.5 mi/kWh
Racing = 1-2 mi/kWh
Example: 100 miles of range at a normal driving pace would require around a 35 kWh pack. Or about 7 modules of the above EV West Tesla Battery Modules
Transmission Options
The intended use will also play a factor here. Whether you intend to retain your manual transmission, use a simple gear reduction, or utilize an adapter plate to mate up an automatic transmission.
If you are using the Complete Tesla Rear Drive Unit, This will contain everything you need for your powertrain.
Conventional transmissions, manual or automatic are designed for internal combustion engines. The multiple gear ratios and ratio spread work well with the RPM-sensitive nature of small gas and diesel engines. For many years, these conventional transmissions were primarily three and four-forward speed units and in automatic, of course, incorporated a neutral, park and reverse mode as well. Over the last two decades, the number of forward speeds has continued to increase in an attempt to squeeze more efficiency out of a less-than-efficient engine design. As the number of forward speeds has increased (now up to ten forward ratios), the size and weight have also increased, and here is the PAIN! Electric car conversions are very weight sensitive and space is always at a premium.
Retaining the conventional multi-speed transmission when converting to electric power is wasteful to the extreme.
Electric motors as a rule are much higher in efficiency and make their peak torque right from a stop and over a much broader rpm range. This means that many electric car conversions could do very well with a smaller, lighter transmission package. In fact, most could do well with a single forward speed reduction gearbox (the ev – TorqueBox®). As an example, all Tesla vehicles use a single-speed gearbox. This is of course true of most all-new plug-in electric cars.
Also, brushless DC and all AC motor conversions do not need a reverse gear in the transmission as they can simply turn the motor in the reverse direction to back the vehicle up.
On-Board Charger
Unless you are building a dedicated race vehicle that never strays far from the pits, it will need to have an On-Board Charger. These modules allow you to connect to standard EV charging points either at home or in public areas.
DC/DC Converter
Unless you are building a dedicated race vehicle that runs for very short periods and has a large enough 12v battery to not need to be charged during use, your EV will need to have a DC/DC converter to keep the 12V battery charged.
To determine what you need, for example, A stock RX8 has a 100A alternator. Multiply this by 13V (a more typical operating/charging voltage) and you get 1,300 watts of power. So whichever DC/DC converter we choose, must have at least 1,300 watts of 12V output power. This wattage may vary for your particular vehicle conversion, but this is a pretty universal alternator wattage for passenger cars to power your lights, wipers, radio, gauges/displays etc
Power Brakes
An electric motor does not produce a vacuum during its normal operation like a combustion engine. You will need a vacuum source supply for your power brake booster and possibly any other vacuum-operated accessories such as heater doors for cabin heating and air condition controls.
Source of vacuum for booster – How much vacuum do I need to run a brake booster?
Any brake booster in the world requires 18 inches of vacuum to operate at peak efficiency.
Another option if you only need brake booster vacuum and do not need vacuum to also run any HVAC controls would be to swap your brake booster for a Bosch iBooster. These can be salvaged from Tesla Model S and Model 3’s as well as some newer Honda.
Bosch iBooster
The Bosch iBooster is an electric brake booster system used in vehicles to enhance braking performance, especially in electrified and hybrid vehicles. It is designed to work in conjunction with regenerative braking systems commonly found in electric and hybrid cars.
Here’s a brief overview of how the Bosch iBooster works:
Brake Boosting:
The iBooster serves as an electromechanical brake booster that amplifies the force applied to the brake pedal by the driver.
Unlike traditional vacuum-based brake boosters, the iBooster uses an electric motor to provide the necessary assistance, making it suitable for vehicles with electric or hybrid powertrains.
Regenerative Braking Integration:
In electric and hybrid vehicles, regenerative braking is used to recover kinetic energy during braking and convert it back into electrical energy to recharge the battery.
The iBooster is integrated with the regenerative braking system to ensure seamless coordination between traditional friction braking and regenerative braking.
Brake-by-Wire Technology:
The iBooster operates on a brake-by-wire system, where electronic signals from the brake pedal are transmitted to the electric motor in the iBooster.
This allows for precise control over braking forces and enables features like brake energy recuperation.
Energy Efficiency:
The integration of the iBooster with regenerative braking contributes to overall energy efficiency in the vehicle.
The system optimizes the balance between traditional braking and regenerative braking, providing effective stopping power while maximizing energy recovery.
Safety Features:
The iBooster is designed with safety features to ensure reliable brake operation even in the event of electrical or system failures.
Redundant systems and fail-safe mechanisms are often incorporated to maintain braking functionality.
The temperature of the battery is important and it needs to be monitored and kept in a relatively tight window. If
it is too cold, it needs to be heated before charging or driving. If it is too hot it needs to be cooled. If you want to extract the absolute maximum performance from the battery it needs to be preconditioned to an exact temperature before use. This requires a fluid heater, a pump, a radiator, a fan, diversion valves, and a VCU to determine what to do and when to do it. The water pump for your battery enclosure can be controlled by something like the AEM VCU
Cooling system for the motor and inverter
The motor and Inverter will make heat and need cooling. It won’t be anywhere near as much as an IC engine makes but it still needs to be dealt with or the inverter will start de-rating the power to protect itself. The cooling system usually includes a cooling loop with a pump, radiator, and fan. In some systems, you may have separate loops for the motor and inverter.
HVAC
Some method of providing cabin heat for the occupants.
Unless you are building a race car with no heat or are in a warm climate, you are going to need to provide some method to generate cabin heat since there is no IC engine generating waste heat that can be used to keep the cabin comfortable.
Some method of providing air conditioning for the occupants. Unless you are building a race car with no A/C or live in a cool climate, you may want to provide A/C for the cabin. EVs don’t have a spinning engine to spin an A/C compressor so you have to install a compressor specifically designed for an EV.
Emergency brake and/or parking pawl
This is a big issue and it is almost never mentioned. EVs almost never have a parking pawl and you can’t leave them “in gear” so a quality E-Brake (preferably automatic activation) is an absolute must.
Throttle Pedal assembly
We have found late-model Ford pedals to be the most consistent and reliable addition to most conversion kits. 2016+ Mustang pedals work well. These also happen to be the same pedals Tesla uses on their vehicles.
FordPart Number: CR3Z9F836C
Brake Pedal Switch
We like the Ford two-position brake switch from a 2016+ Mustang. These have two brake switch inputs that we use as inverse signals so that we have double confirmation signals, much like you do with a DBW Accelerator pedal.
Ford Part Number: GL3Z13480A
Though this will not cover every exact nut and bolt needed for your Tesla Motor Swap Conversion Kit, I hope this will provide enough details to get you on your way or maybe decide whether this is a project you still want to take on.
Though this is far from a complete list of parts and modifications needed to perform a Tesla / EV swap into your Hot Rod or Classic car, Hopefully, it has been helpful.
Kaizen, a Japanese term meaning “continuous improvement,” has long been a blueprint for innovation, from assembly lines to groundbreaking technology. This philosophy—small, relentless improvements creating monumental change—fits seamlessly into the world of hot rods and custom car builds. Think of it as the secret sauce that fuels both precision engineering and creative vision, turning dreams into driveable art.
Kaizen demands patience and diligence—qualities shared by anyone who’s ever hand-shaped a custom fender or tackled the intricacies of a Tesla motor swap. In a scene dominated by bold ideas and fast timelines, this approach reminds us that greatness isn’t built in a weekend. Whether you’re restoring a classic or breaking boundaries with futuristic designs, Kaizen ensures every step contributes to something truly legendary.
Applying Kaizen to Hot Rod and Custom Car Builds
Think of Kaizen as your co-pilot in the shop, guiding you to break down the build into bite-sized brilliance. Start by dialing in the suspension—the unsung hero of handling—before you even think about integrating an electric motor. Each component harmonizes with the next, turning an idea into a symphony of power and precision.
Kaizen also champions methodical planning. Assess what you have, dream of what could be, and then make it happen, one bolt, weld, or wire at a time. It’s not just about avoiding mistakes; it’s about crafting a masterpiece where every piece has a purpose. Documenting each tweak not only sharpens your skills but leaves a roadmap for future innovations.
The Benefits of Continuous Improvement for Hot Rod and Custom Car Builds
This philosophy thrives on creativity and resourcefulness—hallmarks of every great builder. Gradual enhancements give you time to explore cutting-edge tech, like lightweight composites or Tesla powertrains, blending yesterday’s style with tomorrow’s capabilities. And let’s talk sustainability—repurposing old materials isn’t just eco-friendly; it’s a badge of ingenuity.
Picture this: a classic muscle car reborn with an electric motor swap that launches it into the future while respecting its storied past. That’s Kaizen in action. Iterating step-by-step not only builds a better car but also keeps costs manageable, proving that quality doesn’t always have to come with a jaw-dropping price tag.
Kaizen in Action: A Case Study
Take a visionary builder tackling a mid-century cruiser. Instead of starting with an all-out teardown, they revitalize the chassis and brakes first. Next, they integrate a Tesla drivetrain—a whisper-quiet powerhouse delivering instant torque. Finally, they refine the interior, blending retro charm with tech-savvy upgrades. Every stage is deliberate, each improvement compounding the last.
Conclusion
Kaizen isn’t just a philosophy; it’s a way of life for builders who aim for greatness. It’s a relentless pursuit of perfection that turns good cars into unforgettable icons. By embracing continuous improvement for hot rod and custom car builds, you’re not just creating vehicles—you’re crafting legacies, one inspired upgrade at a time.
Vintage vehicles have a timeless appeal that keeps enthusiasts and restoration specialists captivated. Bringing a classic like the Suzuki Samurai into the modern era with an electric powertrain, however, is a bold new direction. This electrified Samurai maintains the rugged, adventurous spirit of the original while embracing a cleaner, greener way to hit the road. The result is a reimagined vehicle that preserves its heritage and adds an eco-conscious twist.
Preserving an Icon
The Suzuki Samurai is celebrated for its simplicity, compact size, and capability. Known for handling tight spaces and climbs with ease, it became a staple in the community of classic vehicle enthusiasts. This electric makeover honors the Samurai’s character, keeping its unique design and capabilities while making it more sustainable. This approach celebrates the past but looks forward to a future where vintage vehicles and modern technology coexist.
Under the Hood: The Electric Upgrade
With classic restorations, a lot of effort goes into maintaining original parts or finding compatible ones. In this Samurai’s case, the restoration was taken in a different direction, balancing timeless design with high-performance electric components. The electric kit includes a Netgain HyPer9 motor producing 120 horsepower and 173 ft-lbs of torque, paired with five 5.2 kWh Tesla battery modules sourced from Legacy EV for ample power storage. The kit also features a manual transmission adapter plate, Dilithium Designs controls, and two Thunderstruck TSM2500 onboard chargers for reliable charging. This setup provides smooth, instant torque and a range that meets the needs of both city driving and backcountry exploring.
Electric Samurai Specifications:
Electric Motor: Netgain HyPer9, 127 horsepower, 173 ft-lbs of torque
Battery Pack: 5 x 5.2 kWh Tesla modules (total 26 kWh)
Charger Compatibility: Two Thunderstruck TSM2500 onboard chargers
Transmission: Manual transmission adapter plate included
Controls: Dilithium Designs Display, MCU and BMS
Staying True to Its Roots
A great restoration often involves respecting the original design, and this project is no exception. The body and interior keep the Samurai’s classic aesthetic, with carefully planned modifications to accommodate the electric motor and battery. With weight redistributed for balance and a lower center of gravity, this Samurai handles even better than its gas-powered predecessor, while still sporting the rugged look that made it a fan favorite.
Modernizing for Convenience
Charging an electric vehicle can be unfamiliar to some vintage car enthusiasts, so this Samurai was built to simplify the experience. The two onboard Thunderstruck chargers ensure that this Samurai can be topped up conveniently. This balance between innovation and everyday practicality makes it a viable choice for drivers who want a classic experience with modern convenience.
Leading a New Wave in Classic Restorations
For many enthusiasts, restoration is about breathing new life into an old favorite, and this electric Samurai embodies that spirit. It’s a project that redefines what’s possible with vintage vehicles, merging the nostalgia of classic designs with sustainable power. This electrified Samurai isn’t just about reducing emissions—it’s a glimpse into how classic cars can adapt to the needs of a changing world.
As the importance of sustainability grows, this project serves as an example of how the vehicles we love can evolve, preparing for a new generation of adventures without sacrificing the character that makes them special. The electric Samurai proves that an eco-friendly twist can breathe fresh energy into vintage cars, ready to take on the road with both style and responsibility.
Drivetrain Specs
Motor:
Netgain Hyper9 with a HyPer-Drive X1 controller, delivering 120 horsepower (89.5 kilowatts)
The 1955 Mercedes 300 SL, one of the most iconic cars in automotive history, has been reinvented with a modern twist—powered by Tesla. The crew behind this project took the elegance and timeless design of the original 300 SL and infused it with cutting-edge Tesla Model 3 performance, creating an electric masterpiece that blends the best of both worlds. It’s like merging old-school charisma with new-school tech, showing that even vintage icons can make a loud statement in the EV world.
Stripping Down the Tesla Model 3 for Maximum Gain
They didn’t just slap on a Tesla motor. The team deconstructed a Tesla Model 3, re-engineering its EV platform to fit seamlessly into the 1955 300 SL’s chassis. Everything from the dual motor setup to the battery pack was meticulously adapted to maintain the original car’s weight distribution and handling dynamics. It’s more than just an electric conversion; it’s a reimagining of what the 300 SL could be in today’s world.
The Blend of Elegance and Power
With Tesla’s electric drivetrain under the hood, the 300 SL is now a beast on the road, boasting around 450 horsepower and an instant torque that would put modern supercars on notice. But what really sets this build apart is that they managed to preserve the timeless beauty of the 300 SL. From the gullwing doors to the curvaceous body lines, it’s all there—only now, it has the heart of a modern electric powerhouse.
Modern Tech Meets Classic Style
It’s not just about the powertrain. Inside, the cabin’s been decked out with the latest tech while maintaining that vintage vibe. A digital Tesla dash replaces the traditional analog gauges, offering all the necessary info at a glance. The interior is trimmed with materials that scream luxury, combining modern comfort with the unmistakable style of the mid-century Mercedes. You get the best of both worlds—a classic car experience with the conveniences of a Tesla.
The Ultimate Head Turner
This build isn’t just an EV swap. It’s a statement—a perfect example of how to respect the past while embracing the future. Whether you’re a classic car enthusiast or an EV fanatic, this Tesla-powered 300 SL is sure to make jaws drop wherever it goes. The attention to detail, the insane performance, and the sheer audacity of the project make it an instant classic in the world of EV conversions.
Feature
1955 Mercedes 300 SL EV
Powertrain
Dual Motor Tesla Model 3 Setup
Horsepower
450 HP
Torque
Instant, approx. 471 lb-ft
Battery Capacity
50 kWh Tesla Model 3 Battery
Range
Estimated 217 Miles
0-60 mph
3.7 seconds
Brakes
Regenerative + Tesla Performance Brakes
Wheels
18″ Classic Mercedes Lookalikes
Technology
Fully operational Tesla autopilot
Sensors
Original Tesla Model 3 sensors
Cameras
Front-facing and side cameras for lane changes and autopilot functionality
Display
Tesla touchscreen display, repositioned for ergonomic fit
This is what happens when West Coast car culture meets the bleeding edge of EV innovation—timeless cool and future-focused speed, all wrapped in a sleek package that says, “Yeah, I’m electric now.”
The automotive world is no stranger to the iconic 1990 Nissan Skyline GT-R. With its renowned performance and timeless design, the GT-R has long been a favorite among car enthusiasts. But what happens when this classic sports car meets modern electric technology? Enter EVzilla, a groundbreaking EV conversion that transforms the GT-R into a green powerhouse, pushing the boundaries of what we thought possible for this legendary vehicle.
A New Heartbeat for a Classic Beast
The EVzilla project breathes new life into the 1990 Nissan Skyline GT-R by replacing its traditional combustion engine with a cutting-edge Tesla P90D Dual Motor Electric Drivetrain. The goal? To maintain the car’s legendary performance while embracing the sustainability and efficiency of electric power.
The Conversion Process
The transformation of the Skyline GT-R into EVzilla is a testament to the dedication and expertise of the engineers and technicians involved. The process begins with the careful removal of the internal combustion engine and associated components. In their place, a powerful electric motor is installed, complemented by 16 5.3kw Tesla Battery Modules and state-of-the-art control systems.
Performance and Specifications
The heart of EVzilla is its electric motor, With 259hp from the front motor and 503hp from the rear motor. which delivers a staggering 762 horsepower! , ensuring that EVzilla retains the GT-R’s signature All Wheel Drive handling and performance characteristics.
A Blend of Tradition and Innovation
EVzilla is not just about performance; it’s about preserving the essence of the GT-R while pushing it into a sustainable future. The exterior of the car remains largely unchanged, maintaining its iconic look. However, subtle modifications, such as aerodynamic enhancements and lightweight materials, help improve efficiency and performance.
Inside, EVzilla features a modernized cabin with digital displays providing real-time information on battery status, range, and performance metrics. The integration of advanced driver assistance systems ensures that the car is as safe as it is exhilarating to drive.
The Road Ahead
EVzilla represents a bold step forward in the world of electric vehicle conversions. By marrying the timeless appeal of the 1990 Nissan Skyline GT-R with cutting-edge electric technology, this project showcases the potential for classic cars to transition into the electric age without sacrificing their identity.
As we look to the future, EV conversions like EVzilla pave the way for a new era of automotive innovation, where sustainability and performance go hand in hand. For enthusiasts and environmentalists alike, EVzilla is a thrilling glimpse into what’s possible when tradition meets technology.
VEHICLE MODIFICATIONS
Category
Description
Performance Electronics
EV Controls T2C, Dilithium BMS System and Charger Controller, AEM CD5 Dash, AEM CCU
Motor
Tesla P90D Dual Motor Setup with Ludicrous Mode
Battery
16 Gen2 5.3kWh Tesla Battery Modules (P85)
Wheels & Tires
Volk Racing TE37 Wheels, Hankook RS3 255/40/17R Tires
Brakes
Brembo Big Brake Kit
Chassis & Suspension
Ohlins Coilovers with Custom EV Spec Springs in Rear for Extra Battery Weight
Exterior
Jun Body Kit, FRP Fenders, Hood, Trunk for Weight Savings, Painted Toyota Voodoo Blue
