Home EV Tips How To Make A Small Electric Car

How To Make A Small Electric Car

Have you ever considered the benefits of driving a small electric car? They are energy efficient, eco-friendly, and maneuverable in congested city streets. In recent years, there has been a surge in demand for electric cars, leading to new innovations in technology and design. However, purchasing an electric car can be expensive, and options for small electric cars are limited. That’s where DIY projects come in. In this blog post, we will guide you through the process of creating your own small electric car, allowing you to save money and customize the design to your preferences.

Select an appropriate battery pack (consider factors like weight and range)

how to make a small electric car

When making a small electric car, selecting the appropriate battery pack is crucial. Factors like weight and range need to be considered carefully. The type of battery affects both the performance and cost of the car. The most common types of batteries used in electric cars are nickel-metal hydride (NiMH) and lithium-ion (Li-ion), while some also use lead-acid batteries.

NiMH batteries are more affordable than Li-ion but have a shorter range and a longer charging time. In contrast, Li-ion batteries offer a longer driving range and a shorter charging time but are more expensive. Therefore, it is essential to find a balance between cost and performance when choosing the battery pack for the car.

The battery pack should also be chosen according to the weight of the car. The heavier the car, the more energy it requires to move, and the larger the battery required. However, a larger battery pack will also increase the weight of the car, thus decreasing its efficiency and range. Therefore, it is important to find the right balance between the weight of the car and the capacity of the battery pack to ensure optimal performance and range.

To summarize, selecting an appropriate battery pack is one of the critical steps in making a small electric car. Factors like cost, range, weight, and efficiency need to be considered when making the decision. Careful selection of the battery pack is crucial to ensure that the small electric car performs optimally and meets the needs of the driver.

Design the chassis and body of the car (consider aerodynamics and space limitations)

how to make a small electric car

Designing the chassis and body of a small electric car requires a careful consideration of aerodynamics and space limitations. At the outset, it is crucial to choose the right materials and dimensions that can handle the weight and power of the electric vehicle.

One of the key design elements is to have a streamlined body that reduces drag and improves efficiency. This can be achieved by creating a rounded front-end and rear-end that smoothly merges into the body. Additionally, the design should also ensure optimal air flow over the car, which can be done through careful placement of the car’s features such as mirrors and windshield.

Another crucial aspect to consider is the interior space limitations, particularly for smaller cars. An electric car needs to accommodate space for the battery and motor system, along with essential safety features, storage, and passenger space. The right balance of all these elements can be achieved by smart design decisions like integrating the battery into the body frame and using lightweight materials to improve the car’s weight-to-power ratio.

Designing the chassis and body of an electric car is a critical step towards creating a functional and efficient vehicle. By prioritizing aerodynamics and space restrictions, car manufacturers can produce a small electric car that is not only sustainable but also practical and enjoyable to drive.

Determine the type of suspension you want to use (consider factors like ride comfort and handling)

how to make a small electric car

When it comes to making a small electric car, choosing the right suspension system is a crucial decision. Factors like ride comfort and handling need to be taken into account before making a decision. There are two common types of suspension systems – independent and dependent.

Independent suspension system offers a more comfortable and smoother ride, as each wheel moves independently and is not affected by the movement of other wheels. This type of suspension is preferred for vehicles that require a high level of handling and maneuverability. On the other hand, dependent suspension system uses a single axle to control the movement of all four wheels. While this system is simple and easy to install, it doesn’t offer the same level of comfort and maneuverability as the independent system.

Ultimately, the type of suspension you choose should depend on the intended use of the small electric car. If you prioritize ride comfort and handling, then an independent suspension system might be the better choice. However, if simplicity is what you are after, then dependent suspension could be the right option. It’s important to carefully weigh your options and consider all the factors before making the final decision on the suspension system.

Install the motor and battery pack into the chassis (ensure everything is securely fastened)

how to make a small electric car

Now that you have designed and built the chassis of your small electric car, it is time to install the motor and battery pack. The motor is the heart of the car and the battery pack provides the power source, so it is crucial to ensure that everything is securely fastened in place.

Firstly, you need to select an appropriate motor and battery pack that will provide enough power for the car’s size and weight. You can choose to buy them pre-made or customize them according to your requirements.

Next, carefully position the motor and battery pack onto the chassis and secure them using bolts and nuts. Make sure that all connections are tightly screwed and there is no movement or rattling of the motor or battery pack.

Once installed, you need to connect the motor and battery pack with appropriate wiring and cabling. This includes connecting the motor to the speed controller and attaching the battery pack to the on-board charger. Double-check every connection and ensure that the wiring is tidy and organized.

It’s important to note that working with an electrical system can be dangerous, so always follow safety guidelines and seek professional help if needed.

By following these steps and making sure that everything is securely fastened, you can successfully install the motor and battery pack into the chassis of your small electric car.

Install the suspension system (ensure all parts are in good condition and aligned properly)

how to make a small electric car

Before you start installing the suspension system in your small electric car, carefully inspect all the parts to ensure they are in good condition and free from any damages. If you find any faulty or damaged parts, it’s recommended to replace them before proceeding.

Once you have all the necessary components in good condition, you can begin installing the suspension system. The first step is to align the suspension in a neutral position before tightening the bolts and nuts. This will ensure that there is no excessive tension or compression on any of the suspension parts, which can cause damage or wear out the components quickly.

Next, you should install the suspension struts and shocks correctly, using the right tools and appropriate torque settings. Doing this correctly helps to maximize the shock absorber’s lifespan and improve the overall handling of your electric car.

Finally, before taking your small electric car for a drive, perform a quick test to ensure that the suspension system is working correctly. Try to drive over some bumps or uneven surfaces to check if the suspension is properly absorbing the shocks and if there are no unusual sounds coming from the car.

By following these simple steps, you can easily install a suspension system in your small electric car and enjoy a smooth, comfortable ride. Remember, it’s always recommended to seek professional advice when doing complex installations or repairs to ensure your car is safe and in excellent operating condition.

Wire the car’s electrical system (including lights, horn, and dashboard)

how to make a small electric car

To prepare the electrical system of your small electric car, you’ll need a wiring diagram and a basic understanding of electrical components. First, determine the location of your car’s battery and motor. From there, you can wire the lights, horn, and dashboard by connecting them to the appropriate wires and fuses according to the diagram. Make sure to use the correct gauge wire for each component and to properly secure all connections with crimp connectors or solder. Before powering up your vehicle, double-check all connections and fuses to ensure they’re all in the correct place and properly secured. Once everything is in place, you can test the electrical system by turning on the lights and horn and checking the dashboard gauges. With a little practice and careful attention to detail, you can wire up your small electric car like a pro.

Test the car’s performance and make necessary adjustments (such as adjusting the suspension)

how to make a small electric car

Now that you’ve finished building your small electric car, it’s time to test its performance to ensure everything is running smoothly before hitting the road. Take your car to a safe and open space, like an empty parking lot or a low-traffic area.

Test the car’s acceleration, braking, and turning ability. Pay attention to any unusual noises or vibrations and take note of them. Check the car’s speed on flat ground and uphill to evaluate its performance.

If you notice any issues, make necessary adjustments. For example, if the car is bouncing too much over bumps, you may need to adjust the suspension. If the car is not turning smoothly, you may need to adjust the alignment.

Don’t hesitate to make tweaks and improvements to ensure your car is safe and efficient. With careful testing and adjustments, you’ll have a small electric car that runs smoothly and meets your needs.

Add finishing touches, such as painting and branding (ensure the car is visually appealing)

how to make a small electric car


Once your small electric car is complete, the finishing touches of painting and branding are essential to make it visually appealing. Painting the car not only enhances the car’s aesthetics but also protects it against rust and other forms of damage. When choosing the color, prioritize a gel coat paint that works with fiberglass or carbon fiber materials and is durable for outdoor use. It’s wise to work with a professional painter who can ensure that the car is painted properly.

Aside from painting, branding your small electric car can give it an identity that sets it apart from the competition. The branding should be unique and recognizable. It could be as simple as putting the company logo on the sides or as elaborate as a full-vehicle wrap with eye-catching graphics.

An important consideration is placing branding in a way that doesn’t affect the car’s aerodynamics, particularly in the case of racing cars. Decals and stickers are also viable options that protect the paint and showcase the brand. Whichever approach is chosen, it should be consistent and reflective of the company’s overall brand image.

In conclusion, painting and branding are the finishing touches that complete a small electric car project. By working with professionals and choosing the right colors and branding, a business can make a statement with its small electric car, which will also be functional, efficient, and environmentally friendly.

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