Converting a gas-guzzler to an hybrid car is not a project for the feint-hearted or for those looking for a reasonable return on their investment. The cost of converting your car to a hybrid powertrain is similar to buying a new hybrid car but much more complicated and time-consuming. If after placing that caveat firmly in your mind, you are still interested in this project, and many are, prepare yourself for a challenge. Of course, the specific hybrid conversion instructions for your vehicle will depend on your car's make and model, as well as your personal driving style and requirements. However, general conversion guidelines can help you avoid some of the pitfalls of a hybrid conversion whatever car you drive.
Choose the right donor model for your conversion. Keep things as simple as possible. For instance, a manual four-cylinder is going to be much easier to convert than an automatic transmission V-6. Look for vehicles with room for your batteries, as you will need it. Small pickups are popular vehicles for hybrid conversions because they are light and have plenty of room for batteries.
Decide what voltage you want or need to supply your hybrid car with. For example, the batteries of a Toyota Prius, a popular hybrid car, provides over 200 V. Connect the battery packs you need to meet your voltage requirements into a series circuit by connecting the positive and negative terminals of each battery with the positive and negative terminals of the next battery.
Install the batteries in the vehicle. The best place to install them will depend on your vehicle. A popular place is behind the back seat or inside the pickup's cargo area, if you chose a light-weight truck.
Install a hybrid vehicle alternator designed to recharge large batteries. Run a wire from your car's alternator to the positive and negative terminals of one of your batteries. This will charge your batteries as you drive and will increase your vehicle's range to as far as your gas tank will take you.
Install an electric motor to your vehicle and connect it to the drive shaft. Again, which model you choose will depend on your vehicle and what you will use it for. The most popular electric motors are series wound direct current motors.
Connect your electric motor to the batteries by running wires from the motor to the positive and negative terminals of one of your battery packs. Make sure your electric motor is designed to run on the voltage your batteries provide.
