Converting a gas-guzzling clunker into a swagged-out, one-of-a-kind EV is all fun and games… until you realize you’re basically playing Tetris with car parts. You have to fit in all the good stuff before your space is filled with garbage. To make things even sweatier, space is tight, options are limited, and if you don’t play your cards right you’ll end up with a Flintstones style car that only goes as fast as your little legs can carry you. All jokes aside, planning your conversion based on space is one of the keys to success, so today we’re going to teach you how to do exactly that.

1. 3D Scan or CAD of Your Car

Before you get too excited, take a step back and do a 3D scan or CAD model of the chassis. Yes, it’s a bit techy, but a necessary part of the process. Portable devices are available that can scan every nook and cranny of your vehicle. Once you have this 3D scan, you can share it with experts who can help you map out the perfect placement for all your components. They’ll calculate weight distribution, emulate driving behaviors, and even suggest necessary upgrades like better brakes or suspension. Plus, this step will save you a ton of headaches when it comes to designing custom parts like motor mounts, battery boxes, and even calculating wire lengths.

2. Prioritize the Essentials of Your EV Conversion Kit

Then, focus on the essentials. Your EV conversion kit isn’t a free-for-all buffet. You can’t just pile on whatever you want. It’s more like a strict diet—especially if your car is just a little guy, and not a Land Rover Defender archetype. First, you’re going to have to focus on squeezing in the battery pack, electric motor, and controller, as these are the core components of any conversion. Carefully plan the layout to make sure these components fit without compromising other crucial aspects like cooling systems.

3. Custom Battery Pack Design

Limited space means you’re going to need to get creative. Design a battery pack that actually fits your car instead of trying to jam a square peg into a round hole. Instead of using a standard battery configuration, see how a modular design fits into your plans. After all, it could allow more battery cells to fit into places you’d never expect.

4. Optimize Weight Distribution

Proper weight distribution is a pillar of good handling. If your vehicle isn’t properly balanced, it isn’t going to handle well—it’s as simple as that. Distribute weight evenly across the vehicle to avoid overloading any one section. And for crying out loud, pick lightweight electric car accessories. You’re building an EV, not a tank.

5. Use Available Space Creatively

As long as you’re smart about it, there’s a high likelihood that you have more space to work with than you think. The trunk, under the seats, even the empty chasm where your old fuel tank used to be—all can be used to accommodate EV components. Custom brackets and mounts can be designed to lock these components down in their new, non-traditional homes.

6. Choose Compact Electric Car Accessories

When you’re dealing with space constraints, compact accessories are your friends. Smaller inverters, tighter charging systems—anything that fits your project and still gets the job done. You want function without the bulk. Save room for the larger, more critical components without losing functionality.

7. Hire a Pro—Because You’re Not One

Let’s face it: this stuff gets complicated fast. There’s a reason people dedicate their entire livelihoods to it. If this is something you actually want done and you’re in over your head, get a professional involved. You can get a consultation, or even get someone to complete the entire project for you. Our guys have seen it all, and they know how to make your EV conversion actually work, and not just on paper.

Handling space constraints in an EV conversion isn’t rocket science—it’s car science. It takes knowhow and a whole lot of planning. If you’re a DIYer, lock in on these basic tips: cut the crap, focus on the essentials, and don’t be afraid to get creative. A well-planned conversion means a car that drives like a dream—not a bad joke. And we all want you to have that. So get in touch with us about your conversion today, and let’s make it happen.