What everyone says you need to build an EV:

Don't be misled!  This is what most people mention when telling someone what they need to build an EV or when they estimate the cost of building one (and even this includes more stuff than most talk about):

Type

Description

Vendors

M

Heat Shrink

Waytek Wire, various EV parts suppliers

M

Aux. Control Relays

Waytek Wire, various EV parts suppliers

M

contactor, main

EV parts suppliers

M

Traction Motor

EV parts suppliers

M

Traction Motor adapter

EV parts suppliers

M

Cable, high voltage and current

EV parts suppliers, welding supply houses, waytek wire

M

Batteries

EV parts suppliers, local battery suppliers, manufacturers, distributors

M

controller

EV parts suppliers

M

Charger

EV parts suppliers

M

Fuses - high current, high voltage

EV parts suppliers

M

Current measuring shunt

EV parts suppliers

M

Current Measuring gage

EV parts suppliers

M

Voltage gage

EV parts suppliers

T

Hammer Crimper or Rachet Crimper for big terminals

Waytek Wire/EV parts suppliers

 

 

 

 

 

 

What you REALLY need to build an EV

This, however, is what you really need, and even this is only the bare essentials.  You may find another tool or a particular material is very useful, and necessary for your conversion.  The novice should know what they are going up against.  Note this doesn't provide any sort of machining capabilities, so you may also need to go to a machine shop for some items/modifications.  As someone has said:  "Calling the past the 'good old days' is a combination of a poor memory and a vivid imagination."  I think reflecting on building an EV is the same way.

Type

Description

Vendors

C

Polyurethane adhesive/caulk

Home Depot/Lowes

C

RTV Silicone Sealant/Adhesive

Auto parts store or wal-mart

C

Noalox (optional)

Waytek Wire

C

VHB Tape or other double faced tape

McMaster-Carr

C

Denatured Alcohol Solvent for cleaning surfaces before putting adhesive mount bases or VHB tape on them

Auto parts store, wal-mart, Home Depot, Lowes (check the paint dept.)

C

Generic Spray Cleaner (like simple green, fantastik, etc.)

Auto parts store, wal-mart, Home Depot, Lowes (check the paint dept.)

C

Welding consumables (tips, rods, wire, etc.)

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, ebay, various welding supply shops, Harbor Freight

C

Corrosion Preventive Compound

Aircraft Spruce and Specialty co.

C

Electrical Tape, vinyl

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

C

Electrical Tape, Liquid

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

C

Electrical Tape, Silicon, Self-fusing

Waytek wire

C

Solder

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

C

Self-etching primer

Auto parts store, wal-mart, JCWhitney

C

Spray-on truck bedliner coating (dupli-color brand)

Auto parts store, wal-mart, JCWhitney

C

Loctite or other threadlocker

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

C

WD-40 or other penetrant

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

F

ALL of a 2-car garage sized workspace (According to several restoration websites, it takes about 3-5 times as much space to hold a disassembled car as it does to hold an assembled car.  An EV conversion will be partially disassembled, and you need room to install the big components)

A garage sale?  Sorry, you're on your own for this one.

H

Lugs

Waytek Wire

H

Battery Terminals to match your battery posts

Waytek Wire

H

Bolts for the lugs, if not included with the various EV items.  Get stainless, there's a miniscule price differential.

McMaster-Carr, Home Depot, Lowes, Harbor Freight

H

Washers - don't let anything rotate against the lead.  Again, use stainless to match the bolt and avoid corrosion.

McMaster-Carr, Home Depot, Lowes, Harbor Freight

H

don't forget lockwashers and nuts while you're at it.  Or Nylock nuts and no lockwashers.

McMaster-Carr, Home Depot, Lowes, Harbor Freight

H

Other nuts and bolts - assorted - usually no. 10 through 3/8"

McMaster-Carr, Home Depot, Lowes, Harbor Freight

H

Self-drilling hex head screws - assorted sizes.  Stainless preferred, though difficult to find.

McMaster-Carr, Home Depot, Lowes, Harbor Freight

H

Crimp-on male and female connectors - best to use at least one that is fully insulated so the completed joint is protected.

Waytek Wire

H

Crimp-on splice connectors

Waytek Wire

H

Crimp-on Ring Terminals, including X and Y terminals

Waytek Wire

H

Wire/cable clamps

McMaster-Carr

H

Ty-Wraps

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes

H

Adhesive mount bases for ty-Wraps

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes

H

Standoffs to mount regulators (for AGM's)

Mouser, digikey, etc.

H

tiny screws to mount regulators (for AGM's)

McMaster-Carr

M

Battery Boots - the ones designed for 'L' terminals are too small - get the ones for auto terminals.  And they don't fit over the heat shrink on cables, so they have to be cut, then glued to the heat shrink using the polyurethane adhesive/sealant.

Waytek Wire

M

Wire, primary, various gages, for low currents.

McMaster-Carr, Home Depot, Lowes, Auto Parts Stores

M

Wire loom

Auto parts store, wal-mart, JCWhitney

M

PVC pipe for running high current cables under car

Home Depot/Lowes

M

Steel Angles, bars. Shapes

McMaster-Carr, Home Depot, Lowes

M

Aluminum angles, bars, shapes

McMaster-Carr, Home Depot, Lowes

M

Threaded rod

McMaster-Carr, Home Depot, Lowes

M

Heat Shrink

Waytek Wire, various EV parts suppliers

M

low current fuses (high voltage)

Mouser, digikey, etc.

M

low current fuses (low voltage)

Waytek Wire

M

Fuseholders

Waytek Wire, Mouser, Digikey, etc.

M

Aux. Control Relays (safety interlock, etc.)

Waytek Wire, various EV parts suppliers

M

Buttons to control aux. control relays from inside the EV

Waytek Wire, auto parts stores

M

contactor, main

EV parts suppliers

M

Contactor, secondary (optional)

EV parts suppliers

M

Traction Motor

EV parts suppliers

M

Aux. Motor (optional, for AC, etc.)

EV parts suppliers

M

Traction Motor adapter

EV parts suppliers

M

Cable, high voltage and current

EV parts suppliers, welding supply houses, waytek wire

M

Battery Regulators (for AGM's)

EV parts suppliers

M

nonconductive plate to mount regulators to (plastic or fiberglass)

McMaster-Carr

M

Batteries

EV parts suppliers, local battery suppliers, manufacturers, distributors

M

controller

EV parts suppliers

M

Charger

EV parts suppliers

M

Anderson quick disconnects, for charger, connecting pack halves, etc.

Wayetk Wire, EV parts suppliers

M

Fuses - high current, high voltage

EV parts suppliers

M

Fuseholders - high current, high voltage

EV parts suppliers

M

Current measuring shunt

EV parts suppliers

M

Current Measuring gage

EV parts suppliers

M

Voltage gage

EV parts suppliers

M

terminal strips

Waytek Wire, Various electronics supply houses, home depot, lowes, walmart

M

rubber mat for vibration isolation and noise dampening (old mousepads work great) - adhesive bond using an appropriate method.

McMaster-Carr, etc.

M

Ceramic Heater Core

EV parts suppliers

M

Nonconductive plate to mount heater core in/on

McMaster-Carr, Home Depot, Lowes

M

High voltage Relay or Contactor for Heater Core

EV parts suppliers

M

Snubber/arc supressor network for heater relay

EV parts suppliers

M

Charger Adapters to be able to use multiple outlets

Get parts from Waytek wire, Home Depot, Lowes, RV supply places, etc.

M

Service/emergency disconnect

Waytek wire, EV parts suppliers

P

Rubber gloves for when dealing with chemicals, including battery acid

Home Depot/Lowes/Walmart

P

Safety Glasses

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

P

Safety Goggles (use instead of glasses when you have to be under something you are spraying or grinding)

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

P

Welding Helmet

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, ebay, various welding supply shops, Harbor Freight

T

Caulk gun for dispensing adhesive/sealant

Home Depot/Lowes

T

Hammer Crimper or Rachet Crimper for big terminals

Waytek Wire/EV parts suppliers

T

Flat blade screwdriver, large

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Flat blade screwdriver, small

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Flat blade screwdriver, 90 degrees

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Flat blade screwdriver, stubby

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Phillips head screwdriver, large

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Phillips head screwdriver, small

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Phillips head screwdriver, 90 degrees

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Phillips head screwdriver, stubby

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Hammer, small

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Hammer, large

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Fluorescent Trouble Light or paint light (low heat output required to avoid setting things on fire)

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Welder

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, ebay, various welding supply shops, Harbor Freight

T

Cordless Drill with tool assortment

Harbor Freight, walmart, lowes, home depot

T

Corded Drill

Harbor Freight, walmart, lowes, home depot

T

Jigsaw

Harbor Freight, walmart, lowes, home depot

T

Soldering Iron

Auto parts store, wal-mart, JCWhitney, Home Depot, Lowes, Harbor Freight

T

Heat gun or Propane Torch (for heat shrink - also good for heating acrylic for bending)

wal-mart, Home Depot, Lowes, Harbor Freight

T

multimeter (a good one)

Various electronics supply houses, home depot, lowes

T

multimeter (an inexpensive one)

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

hydrometer (for floodies)

battery supply houses, auto parts store, walmart

T

Torque wrench

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Socket set, SAE

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Socket set, deep well, SAE

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Socket set, Metric

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Socket set, deep well, Metric

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Open End Wrench Set, SAE

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Open End Wrench Set, Metric

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Crescent Wrench Set

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

breaker Bar

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Spring clamps - assorted

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Vise Grip Pliers - assorted

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Clamp/spreader - assorted

Harbor Freight, Auto parts store, walmart, lowes, home depot

T

Power Strips for running multiple tools/lights/chargers at the same time

Harbor Freight, walmart, lowes, home depot

T

Extension Cords

Harbor Freight, walmart, lowes, home depot

T

Hoist for removing the ICE and installing the motor

Harbor Freight, JCWhitney, Walmart, Auto Parts Stores

 

 

 

 

T = Tool

 

 

C = Consumable

 

 

H = Hardware

 

 

M = Material

 

 

P = PPE (personal protective equipment)

 

 

F = Facility

 

 

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