Technical

From hand-built electric motorbikes to professional-grade vehicle conversions, the Battery Vehicle Society has long stood at the intersection of enthusiasm and engineering. Our members have decades of collective experience designing, building, maintaining, and improving electric vehicles of all kinds. This Technical Resources page is a curated guide to the essential tools, information, and support systems that both newcomers and seasoned tinkerers can draw upon.

Whether you’re building your first EV from scratch, retrofitting a classic car, or simply trying to understand how a lithium battery management system works, you’ll find practical help here—grounded in real-world experience and written with the BVS spirit of sharing and ingenuity.

Getting Started: Understanding the Basics

Electric vehicle technology may seem complex at first, but it’s rooted in principles that are well within reach for any curious mind. These are the core systems worth mastering:

  • Battery Packs – The heart of any EV. Most modern builds use lithium-ion cells (such as 18650 or prismatic formats), but older builds may still use lead-acid or nickel-metal hydride. Understanding voltage, capacity (Ah), and series/parallel configuration is essential.

  • Motors – From brushed DC motors to sophisticated AC induction or permanent magnet synchronous motors (PMSMs), choosing the right motor depends on your project’s size, budget and power needs.

  • Controllers & Inverters – These devices regulate the delivery of power from battery to motor. Open-source options (like OpenInverter) are popular among DIYers, while proprietary systems offer plug-and-play reliability at a higher cost.

  • Charging Systems – EVSE (Electric Vehicle Supply Equipment) compatibility, on-board chargers, and DC fast charging are all areas that merit exploration depending on your setup.

To get up to speed, we recommend the BVS-published EV Beginner’s Handbook, available to members, which covers foundational knowledge with diagrams, examples, and safety tips.

Converting a Vehicle: Step-by-Step Guidance

Vehicle conversions are a cornerstone of the BVS community. Many members have converted classic Minis, VW Beetles, Land Rovers, and even milk floats to electric propulsion. The process can be broken into several key stages:

  1. Planning & Design
    Start by assessing the donor vehicle’s weight, space, and structural integrity. Determine your goals: urban runabout? Show car? Performance project?

  2. Removing the ICE (Internal Combustion Engine)
    Strip out the engine, fuel system, exhaust, and cooling system. Some vehicles are more conversion-friendly than others, due to chassis layout or gearbox accessibility.

  3. Selecting Components
    Choose a suitable motor, controller, and battery system. Reuse parts where possible—for instance, many opt to retain the original gearbox and clutch.

  4. Fabrication & Mounting
    Fabrication may be required for motor mounts, battery trays, and enclosures. Safety is paramount here—consult local MOT regulations and consider professional welding services for critical components.

  5. Wiring & Integration
    This step involves connecting high-voltage and low-voltage systems, integrating throttle and brake signals, and ensuring battery management systems (BMS) are correctly configured.

  6. Testing & Tuning
    Test at low speeds first, then gradually increase load. Log performance data and fine-tune the controller’s settings for efficiency or torque as needed.

The BVS maintains a library of past member projects, complete with wiring diagrams, CAD files, and lessons learned—available to all Society members.

Tools & Equipment

A well-equipped workshop makes all the difference. Depending on your project, here are some commonly used tools and diagnostic gear:

  • Multimeters & Clamp Meters

  • High-voltage gloves and insulated tools

  • Battery spot welders (for custom packs)

  • Torque wrenches and jacks

  • CAN bus readers for modern EV components

  • Oscilloscopes for advanced diagnostics

The BVS also offers guidance on sourcing parts affordably—whether salvaging components from written-off EVs or purchasing new from trusted suppliers in the UK and EU.

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