Electric Conversion Guide

An electric conversion – also called an EV conversion or retrofit – means that the combustion engine of an existing vehicle is replaced by an electric motor with a battery pack. Body, chassis and interior are retained. So you keep your vehicle and give it a new, emission-free life.

The process typically runs in six phases: first, the vehicle and requirements are analysed. Then the combustion engine, including tank, exhaust and, depending on the configuration, the gearbox, is removed. In the third step the electric motor with motor control is installed, followed by the installation of the battery pack. Then the charging port, air conditioning and auxiliary consumers are integrated. The TÜV individual approval concludes the process.

The decisive difference from buying a new electric car: with a conversion you save the resource-intensive new production of a body. You use existing substance, avoid the bulk of the production emissions of a new car (around 7–12 tonnes of CO₂) and keep a vehicle that is close to your heart. Especially with classics like the Porsche 911 or VW Beetle, that is an unbeatable argument.

In principle, almost any vehicle with a combustion engine can be converted to electric drive. In practice, however, some vehicles are better suited than others. The three decisive factors are: space for the battery, the vehicle weight and the availability of suitable drive technology.

Classics & vintage cars

The most popular segment for electric conversions. Vehicles like the VW Beetle, VW Bulli (T1/T2/T3), Porsche 911/912/914 and Mercedes W123/W124 offer sufficient space and a loyal community. The simpler mechanics of older vehicles often make the conversion less complicated than with modern cars. In addition, the value of a professionally electrified classic rises considerably – a Porsche 911 with electric drive and TÜV certification becomes a real collector item.

Everyday Vehicles

Modern everyday cars are also suitable for conversion, especially if the vehicle is still in good mechanical condition but the engine is defective or causes high running costs. Vehicles with emotional value – the first car, an heirloom – thereby get a second life. The prerequisite is that a TÜV individual approval is possible.

Commercial Vehicles & Special Applications

Vans, construction machinery and even stationary applications like home storage for PV systems can be equipped with electric components. ESDI assemblies are versatile and not limited to passenger cars.

Electric motor

Modern electric motors deliver full torque from the very first moment – a noticeable difference from the combustion engine, where the power first has to be revved up. Depending on the configuration, speeds of 120 to over 200 km/h are possible. For everyday use and most classics, 130–160 km/h is entirely sufficient, matching the original or even surpassing it.

Battery Technology

The battery is the heart of every electric conversion and at the same time the biggest cost factor. Two technologies dominate the market:

Lithium-Eisenphosphat (LFP) – These cells are particularly durable, safe and thermally stable. They are the ideal choice for classics and everyday vehicles where reliability takes priority over maximum range.

NMC-Zellen (Nickel-Mangan-Cobalt) – Higher energy density means more range per kilogram. The right choice when maximum range is required in limited installation space.

Modern lithium batteries last 150,000 to 300,000 km or 8 to 15 years. The capacity drops by about 20–30% over the entire lifespan. A professional battery management system (BMS) – as integrated in ESDI kits – monitors every single cell and thus maximises the lifespan.

Range – what is realistic?

The range depends directly on the battery capacity. As a rule of thumb you can reckon on 15–20 kWh consumption per 100 km, depending on vehicle weight, air resistance and driving style. Concretely that means:

With 10–20 kWh of capacity you reach 80–150 km – ideal for city traffic. 20–40 kWh brings 150–250 km for daily everyday use. And with 40–60 kWh, 250–350 km of long distance is possible. Use our Range Calculatorto determine the right configuration for your vehicle.

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Transmission, Regenerative Braking & Auxiliary Systems

In most conversions the gearbox is removed and the electric motor is coupled directly to the drive shaft. In some vehicles – such as the VW Beetle – the gearbox can be retained. Regenerative braking, that is, the recovery of energy when decelerating, is available in all ESDI conversions and can be switched off in various stages. This increases the range and spares the mechanical brake.

Auxiliary units like power steering, air conditioning, cruise control and auxiliary heating can be replaced by electric equivalents. The integration requires experience – here lies a key advantage of professional conversion kits over self-build solutions.

The total costs of an electric conversion depend on three factors: the vehicle type, the desired range and the scope of the conversion (kit vs. individual development).

Cost Framework

The largest single item is always the battery – the more range, the more expensive the battery pack.

Long-Term Savings

What appears expensive at first glance pays off over the lifespan. Electric vehicles have around 90% fewer wear parts than combustion cars. No oil change, no timing belt, no exhaust system. The annual maintenance costs drop from €500–800 to about €100–200. Added to this are savings on fuel (around €1,500–2,500 per year) and vehicle tax (€300–500 per year). Over 10 years a conversion can work out €20,000–30,000 cheaper than running a combustion car.

Funding & Financing

Currently there is no direct federal subsidy in Germany specifically for electric conversions. After the conversion, however, you benefit from the reduced vehicle tax and can apply for an E-license plate. Instalment payment is possible at many workshops – the saved petrol costs of €100–200/month can partly cover the financing.

Electric conversions are fully legal in Germany, provided they pass a TÜV individual approval under §21 StVZO. The change is entered in the vehicle papers and the vehicle is subsequently registered for road use without restriction – including the motorway.

What is checked at the TÜV approval?

The TÜV checks five areas: electrical safety (insulation, contact protection, emergency shut-off), mechanical mounting of all components, EMC compatibility (electromagnetic compatibility), brakes and driving behaviour under the changed weight distribution, and the complete technical documentation. ESDI supplies the required reports and documentation for all kits, so that the approval usually runs smoothly.

E-Kennzeichen & Vorteile

After a successful TÜV approval you receive an E-license plate. The advantages: free parking in many city centres, use of bus lanes (depending on the municipality), reduced vehicle tax for 10 years and access to all low-emission zones. Important for classic-car owners: the H-plate is usually lost, since the drive no longer corresponds to the original condition. However, the E-license plate often offers more attractive advantages.

Insurance

You must inform your insurer about the conversion. The good news: most insurers classify EVs more cheaply. The costs often drop by 10–20% compared with the combustion car.

Charging at home and on the road

With every professional conversion a Type 2 charging port is installed – the standard in Europe. With it you charge at every public charging station, at your own wallbox and, if necessary, at the household socket. With an 11 kW wallbox your vehicle is full in 3–6 hours. At the household socket it takes 8–15 hours overnight. ESDI kits include a compatible on-board charger.

Winter Operation

In cold weather the range drops by around 15–30%. With battery preheating the loss can be reduced to 10–15%. ESDI offers cooling plates and thermal pads for optimal temperature management – both in winter and in summer heat.

Maintenance

An electrified vehicle needs considerably less maintenance than a combustion car. At least once a year a service check should be carried out, in which wear parts, operating fluids and fastenings are checked. Every two years the main inspection and brake-fluid change are due. That is it. No oil changes, no timing belt, no spark plugs.

Reversibilität

A professional electric conversion is fully reversible. The original engine can be reinstalled at any time. This is especially important for classic-car owners who want to keep the original condition as an option.

An electric conversion is the most sustainable form of mobility. Instead of producing a new vehicle – which alone causes around 7–12 tonnes of CO₂ – you continue to use the existing body. Over the lifespan you reduce your CO₂ footprint by 60–80% compared with a combustion car.

There are sustainable solutions at the battery end of life too: lithium batteries are recycled and the valuable raw materials recovered. Before that, they can still be reused as stationary energy storage – for example for solar systems (second life). Thus an old car becomes a building block of the energy transition.

Are you ready? Here is how to proceed:

Find your model: Use our Model Finderto find the right kit for your vehicle.

Calculate the range: Our Range Calculator zeigt Ihnen, welche Konfiguration zu Ihrem Fahrprofil passt.

Schnelle Antworten: In unserer FAQ you will find concrete answers on prices, times and process at ESDI.

Get advice: Kontaktiere uns for a non-binding consultation – whether you are a private individual, workshop or dealer.

Teile durchstöbern: In unserem Shop you will find individual components and complete conversion kits.

As of March 2026 | All information without guarantee. For individual questions: info@esdi-ev.de