What Commercial Shops Need to Know Before Offering EV Conversion Services

You’ve built a business on combustion—engine swaps, drivetrains, diagnostics, fabrication, maybe the occasional resto-mod. But now, the calls are trickling in:

“Can you convert my classic to electric?”

“What’s it cost to do a Tesla swap?”

“Do you work on EVs?”

You know the tide’s turning. The EPA isn’t exactly pulling punches. States like California are putting internal combustion engines on a clock. And the aftermarket world? It’s catching up fast.
But before you dive into EV conversions as a commercial shop, pause. Because this isn’t just a new drivetrain—it’s a new business model. And if you want to do it right (and profitably), there are a few things you need to know before you hang that “Now Offering EV Conversions” sign.

1. EV Conversion Work Isn’t Plug-and-Play—It’s System Engineering

This isn’t just ripping out a gas motor and bolting in a battery pack. EV conversions are holistic systems:

1. Motor + inverter

2. Battery + BMS

3. Charger + DC-DC converter

4. Cooling systems + safety cutoffs

5. Wiring looms + CAN integration (yep, you’re learning CANbus)

You’re now integrating high-voltage systems across an entire vehicle. Every component needs to play nice—or you’re in for a lot of smoke, error codes, or worst-case: fire. You’re not just building a powertrain; you’re building infrastructure inside a car.

That means hiring—or becoming—someone who speaks both “mechanic” and “electrician.” At minimum, you’ll need:

A certified high-voltage technician on staff

Solid wiring and electrical diagnostic capabilities

A fabrication team that can handle mounts, housings, and cooling lines

2. Kits Are a Shortcut—But They Don’t Replace Expertise

Some of the most capable and forward-thinking EV conversion shops today are part of the Fuel2Electric network. These aren’t one-off hobbyists—they’re experienced builders who’ve already worked through the quirks of second-life Tesla modules, mastered thermal management, and figured out how to deliver clean, safe, and road-ready conversions.

When you work with a Fuel2Electric member shop, you're tapping into a vetted community that knows how to make high-voltage systems behave reliably inside everything from classic VWs to 4x4s.

But here’s the trap: kits don’t make your shop plug-and-play. You still need to:

1. Modify mounts to fit the chassis

2. Manage weight distribution and suspension adjustments

3. Install thermal management for batteries and inverters

4. Program controllers and throttle maps

Kits help, but they’re not Legos. Your team still has to fabricate, wire, test, and tweak. Which means if you’re treating these jobs like a bolt-on turbo kit, you’re not ready yet.

3. Pricing Is Tricky—And Labor Is the Wildcard

Let’s talk brass tacks. The average EV conversion using repurposed Tesla components costs $18,000–$25,000, while full turnkey kits with new parts (motor, batteries, chargers, BMS) can run $30,000–$60,000+ depending on range and performance expectations.

But here’s what most shops miss: labor is often 100–200 hours per build when replicating an existing build. A new build sometimes takes 500-600 hours. That includes:

1. Custom wiring

2. Controller configuration

3. Battery mounting and enclosure fab

4. Cooling integration

5. Troubleshooting and testing

If you’re not charging at least $100/hr for EV work, you’re going to eat it. Underestimate labor and your margins disappear faster than your coolant during a thermal runaway.

4. Insurance, Liabilities, and Legal—Yes, You Need to Care

This part? Not fun, but critical.

EV conversions move you into a new regulatory space:

UL ratings? Your components better meet safety standards.

High-voltage safety? You’re dealing with up to 400V+ DC—touch the wrong wire, and it’s fatal.

` Many shops don’t realize their garage liability won’t cover an EV pack fire.

Some states (like California, Colorado, and New York) also have emerging requirements around certified EV technicians and post-conversion inspections for road registration.

You’ll want:

1. A separate commercial liability policy for EV work

2. Written disclaimers and client sign-offs on custom builds

3. A solid understanding of how your local DMV treats converted EVs

This isn’t legal paranoia—it’s business risk management. One battery thermal event can put you out of business without a proper umbrella.

If you’re working with Fuel2Electric, this level of protection isn’t optional—it’s required. To ensure comprehensive protection for both shops and clients, all member vendors must provide proof of insurance every time they’re awarded a project. This includes, at minimum, general liability and garage keeper’s insurance. If your coverage isn’t up to par, you’ll need to upgrade before taking on any jobs through the platform. It’s not red tape—it’s what separates professional operations from risky side gigs.

5. You Need a Different Kind of Marketing Funnel

If your current pitch is “We build badass cars,” that’s great. But EV conversion clients want:

1. Reliability

2. Transparency

3. Environmental value

4. And often… a modern dash of nerd

5. Your new audience is a mix of:

6. Classic car owners who love the aesthetics but want green power

7. Fleet managers converting to meet ESG goals

8. EV-curious drivers looking for long-term ROI

9. DIYers who want help finishing a half-done project in their garage

10. Build content that meets those needs:

11. EV range calculators

12. Blogs on Tesla module integration

13. FAQs about conversion pricing

14. Before-and-after dyno results

15. Case studies showing real range, weight, and cost data

And yes—this means you’re not just building cars anymore. You’re educating your buyers, shaping the future of custom EVs, and building a name for yourself in a growing market.
Fuel2Electric supports that visibility. We actively promote standout shops through social media, newsletters, and events—and we invest real time and money into showcasing the best builds and the builders behind them. If you're doing great work, F2E helps make sure the right people see it.

6. Sourcing Batteries? You’d Better Have a Plan

Want to sell EV conversions without reliable battery sourcing? Don’t.
Right now, good second-life Tesla modules are in high demand—and prices are volatile. You’ll want:

A vetted supplier

Quality control tools to test State of Health (SOH)

Relationships with local recyclers or salvage yards for parts streams

And if you’re not ready to deal with liquid cooling, contactor failures, or balance charging? Start smaller. Maybe offer EV-safe welding and fab services before going full tilt.

Final Thoughts: Start with Systems, Not Just Swaps

If you’re planning to add EV conversion services to your shop, don’t treat it like a fad. Treat it like a strategic pivot into a new market. That means:

1. Training your staff

2. Pricing like a systems integrator, not a mechanic

3. Vetting suppliers

4. Investing in diagnostic gear and safety equipment

5. Educating your market—one build at a time

Because EV conversions aren’t just about electrifying the classics. They’re about future-proofing your shop. And if you get it right, you won’t just be ahead of the curve—you’ll be the one building it.

Need help speccing a kit for a client? Want to talk shop on Tesla module layouts or wiring diagrams? Reach out—we work with builders every day to turn combustion expertise into electric know-how that scales.