3.Dismantle
• Disconnect and remove battery
• Drain and properly dispose of antifreeze and engine oil
• Disconnect wiring harness
• Remove engine (retain until design measurements are taken)
• Remove cooling system
• Remove exhaust system
• Remove fuel system
4. Design new systems
• Motor support (using engine & transmission centerline measurements)
• Motor to transmission adapter (using engine & transmission measurements)
• Power Steering
• Air-conditioning
• Battery support, containment and ventilation
• Layout of components
5. Order or fabricate vehicle-specific components
6. Order motor and motor clamp/mount
7. Install motor
• When motor arrives, run (seat) brushes using 12 volt battery
• Mount flywheel to motor and bench test for balance and vibration using 12 volt battery
• Install motor using motor-to-transmission adapter and motor mount
• Elevate drive wheels and test drive train using 12 volt battery
8. Order off-the-shelf conversion components
9. Install mechanical systems (except suspension modifications)
• Air conditioning
• Power steering
• Vacuum system
10. Install battery boxes
• Mount boxes securely to vehicle frame
• Provide reinforcement if any modifications are made to vehicle structure
11. Install high-current components
• Controller
• Contactor(s)
• Circuit breaker
• Fuse(s)
• Shunt(s)
12. Install low-current components
• Throttle pot box
• Controller pre-charge resistor(s)
• Auxiliary battery
• Auxiliary fuse panel
• Instrumentation
-Speedometer
-Tachometer
-Amps
-Volts (battery pack)
-Volts (auxiliary system)
-Link-10 meter
• Heating
• Air-conditioning wiring
• Vacuum pump, switch, etc. to restore power brakes
• RPM limiter
• Inertia switch
• Battery charger
• Battery charger interlock
13.Purchase batteries
14. Install batteries
• Batteries
• High-current cabling
15. Stationary testing
• Subsystems
• Drive train
16.Road Test
17.Certification
