Pioneer Conversions L.L.C.

12305 South New Avenue, Suite N
Lemont, IL 60439
Phone: 630-243-6616
Fax: 630-243-6582




    Who is Pioneer Conversions?

        A group of active Electric Vehicle enthusiasts, who believe in reasonable cost EV (Electric Vehicle) conversions as a means of transportaton.

    Why convert a car to electric power?

        Several factors, including better energy resource consumption, lower operating expenses, less maintainance.  The primary motive for many EV people is lack of the need to purchase gasoline.  You will be able to quietly roll by countless gas stations, and laugh at their prices.  You'll refuel by charging at home, likely overnight.

    What's different about Pioneer Conversions?

        -    A myriad of professional experience in converting cars over decades of conversions
        -    A plan to offer used electric powered automobiles for sale, with their conversion completely, professionally done.
        -    Professional selection of the best available parts
        -    Purchasing of motors, controllers, batteries in quantity will mean lower finished product prices

    Illinois offers a rebate to anyone converting an electric vehicle, how does that fit in?

        Illinois does offer this rebate.  Anyone doing the conversion needs to document the conversion.  The rebate can be up to $4000, which Pioneer Conversions will pass along in the sale of the completed conversion.  The purchaser will not have to save paperwork, pick parts suppliers carefully, and will not have to submit all the pieces of the rebate to the State of Illinois and wait for thier rebate check. Pioneer Conversions will handle all the paperwork for this.

    Who will service my car?

        -    For the original parts that are not part of the conversions, like door handles or trunk locks, your regular service mechanic will be perfect.
        -    For those parts related to the conversion, Pioneer Conversions will perform any needed service.
        -    Please keep in mind that much less service will be needed for a vehicle powered by electricity.

    What do you mean, less service will be needed?

        -    You will not need engine tune-ups, the electric motor will run well for many years
        -    No periodic oil changes.  You may have to put your own windshield washer fluid in.
        -    You will not need any mufflers, exhaust, or catalytic converter repairs or replacements.
        -    You will not need to undergo emission checks, as your car produces no emissions
        -    You will not need any radiator service or other parts associated with the internal combustion engine.

    How much will it cost to drive an electric vehicle?

        Good studies done by reliable people, when comparing almost identical vehicles, show an energy savings of 75 to 80%. When you compare a Geo Metro in its original gasoline powered version with a Geo Metro converted to electric power, the EV energy costs about 20 - 25% of the cost of getting the energy from gasoline. Much of the energy created by gasoline is wasted as heat, and the gasoline engine must be cooled, discarding this heat to the atmosphere. Similar studies with S-10 pickup trucks have confirmed this cost. These studies were done when gasoline prices were about $2 a gallon. The studies do not include service and maintenance costs, which further favor the electric conversion.

    How much will it cost to convert a car to an electric vehicle?

        There are many variables when converting a car to an electric vehicle. Most of the conversions that leave our shop cost about 12,000 to 15,000 for the conversion. Most conversions are capable of freeway speeds and reasonable acceleration. A range between recharges of 30-40 miles is common. If you don't mind adding some water to the batteries yourself, a "flooded" lead acid battery is a reasonable choice, saving some money on the initial price. AGM cells need much less maintenance, but increase battery costs and need a balancing system. NiMH and Li-ion batteries are also available, but costs dramatically rise with these choices. Most of the conversions have normal amenities, but it does take some additional engineering to make power steering, air conditioning, and cabin heat work effectively. Most cars chosen for conversion to electric have reasonable suspensions and bodywork. However, if you choose one of the smallest cars available, and plan to add several hundred pounds of batteries, you will need to modify the suspension significantly.

    Right now we are working on a brand new Toyota, and converting to Li-ion batteries. This will be an exceptional car, but the cost of the batteries alone will exceed the price of some of our total conversions.

    I'm in the process of planning an EV conversion of a Chevy S-10 pickup. I'm interested in the TransWarp9 motor with the drive shaft connectivity.

        -    Several folks have tried to use electric motors connected directly to the drive shaft of a rear wheel drive vehicle. Yes, this can work, and we even sell a TransWarP series of motors that were initially designed for that application. Trans WarP motors have a "shorty" tail shaft housing from a Chevrolet Turbo 400 transmission fitted to the drive end-bell. This really helps when your need to connect two motors head to tail for additional power (or acceleration like our dragster) or when used in the EMIS hybrid system. See http://www.go-ev.com/EMIS.html and http://www.go-ev.com/EMIS-dealers-usa.html

    The biggest disadvantage to connecting a TransWarP to a driveshaft to the differential, is when connected in this manner, there is no means of disconnecting the motor from the drive shaft. No neutral, no clutch to release, no way to disengage the power. We feel that such a disconnect is a very significant safety issue, and do not recommend the use of a TransWarp for street use. If you were using it in a dragster, we would have a different recommendation.
    You are right in thinking that a direct drive of the driveshaft in an S-10 or similar vehicle would leave the motor at a sub-optimal RPM, but this is not likely a large factor unless you are racing. When installing an electric motor in a STICK S-10, the owners/drivers usually leave the vehicle in third, sometimes fourth. The additional ratio of the gearbox and the differential seem to be more appropriate to the electric motor in normal use.

    What are Pioneer Conversions terms and conditions to undertake a convertion project?

        -    A detailed estimate is free. We STRONGLY suggest you research the possible choices, so that we can suggest a combination of parts and services to your needs. For motors, parts, batteries, controllers and various parts, we expect payment when when ordered (if special order) or when delivered (for those items in our stock) We would require a 75% deposit on custom machining, engineering, or fabrication, before any work is started, payment in full when delivered. We accept cash, check (with an appropriate wait for bank clearance) or money orders (must be made out to us, for the exact amount). We are aware of several scams that involve overpayment or fraudulent money orders, and protect ourselves from these scams. We keep our prices low by being careful about accepting bogus payments. Please discuss payment options with us, before ordering.

    What items cost the most in conversion to an electric vehicle?

        Sometimes the batteries are the biggest expense.
    Some ball park prices:
       
    Flooded Lead Acid Batteries - $2000 - 3000
       AGM Batteries - $3000 to $4500
       Nickel Metal Hydride - $7000 - 9000 when available
       Lithium Ion - Currently above $30,000
       Controller for power - $2400 - $3000
       Motor - $1700 - 3000
       Battery Regulators - $1000 to $1500
       
    There are also many small items to add, such as a potentiometer (to provide a smooth, variable accleration), a 'fuel' guage, a DC/DC converter to run the standard 12 volt system of the car, a main contactor, main fuse(s), a circuit breaker, a connection for charging, at least one charger, perhaps a second 110 volt charger in the car, and wiring, cables, and adapters for the motor, for the electronic boards, and a method of securing the batteries.

        Frequently the largest single item on the final bill is the labor. Labor varies widely in the time and engineering it takes to convert a car to electric power, but this item usually runs over $5000 by itself.

    I have a large pickup truck, and need to convert to electric power. Can I get a range of 150 miles? I need freeway speed for much of my travel, some will have a small trailer.

        Well, it is possible to mate an electric motor to your transmission, but difficult for two reasons. The adapter plate, shaft coupling, and brackets would all have to be custom engineered, driving up the cost. If the vehicle is a stick shift, this is possible, but becomes much more difficult if it is an automatic. If it is an automatic, someone has to determine how to make the trans stay in second, and to not use torque multiplication, etc. Since the trans controls are partly mechanical, partly electrical, and partly hydraulic, this is difficult, especially if it hasn't been done before. A large 4x4 pickup isn't the most energy efficient vehicle, and with lead acid batteries, you would have a short range before you would have to recharge. If you were to convert to pure electric, you might not be satisfied with the abilities of the vehicle. NiMH batteries would increase your range, but would not approach 150 miles of range even under the most ideal of condtions. Even with more than $30,000 of Lithium Ion batteries, I don't think we could get 150 miles of range in your truck. On the other hand, perhaps a hybrid electric motor will help you. Take a look at the EMIS package that Netgain Technologies offers. This adds an electric motor and controls the package linking through the OBDII port. This might be a very workable solution. See:
    EMIS videos
    Hybrid Panel Van (Pie Truck)
    S-10 Blazer

    I have read that the Transwarp can be operated without an OEM transmission. Do I just adjust the driveshaft for length and run the motor straight into the differential.

        You can, but we do not recommend this for street driving. The best use of the TransWarP is in a drag situation or as a hybrid. For street use, we strongly feel you should run a trans, a clutch, or a way to disconnect the motor from the drive wheels as a safety factor. This is not possible if you connect the TransWarP straight to the drive shaft.


    What is the policy of Pioneer Conversions on returns?

        We occasionally are asked about returns of items we have sold. Our policy: Returns must be new, unused, and with original packing and all parts, including instructions. A 20% restocking fee will apply to any parts returned. All returns will be at our discretion, and require prior approval. Call us, or email us with requests first.

 

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