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Systematically test and calibrate all systems before the vehicle is driven. Each test protects against failure during operation. Do not skip any step — this is the most important phase of the entire conversion.

Install the onboard charger (OBC) and Type 2 charge inlet. A Type 2 (IEC 62196) socket allows 7.4kW single-phase or 22kW three-phase AC charging. Proper earth fault protection and isolation monitoring is mandatory.

Install a dedicated liquid cooling loop for the battery pack, motor, and inverter. Proper thermal management extends component lifespan from ~1000 cycles to 2000+ cycles and maintains performance in all conditions.

Install the high voltage (HV) wiring between battery, inverter, and charger. All HV conductors must be orange-jacketed as per IEC/EVSA standards, routed in conduit, and protected from mechanical damage.

Install the motor inverter and Vehicle Control Unit (VCU). The VCU manages the whole system via CAN bus, interpreting throttle inputs and communicating with the BMS, inverter, charger and dashboard.

Install the lithium iron phosphate (LiFePO4) battery pack in custom steel enclosures. LiFePO4 is strongly recommended for its thermal stability and safety. Enclosures must provide structural protection and crash resistance.

Install the electric motor using a custom adapter plate. Precision alignment with the drivetrain centreline is critical – even 0.1 mm of misalignment causes premature bearing failure and vibration.

Remove the internal combustion engine, fuel system, exhaust and all associated components. Drain all fluids first and ensure the vehicle is safely supported on rated axle stands throughout.