A Creative Solution to Engine Failure

While electric vehicle conversions are frequently associated with high-end luxury projects costing small fortunes, a growing community of DIY mechanics is proving that going electric doesn't have to break the bank. A notable example comes from the YouTuber known as Life of Troy, who recently turned a damaged 1996 Suzuki Jimny (the international counterpart to the Suzuki Samurai) into a functional EV in under a week.

The project was sparked by necessity. After importing the vehicle from Indonesia, the 1.0-liter four-cylinder engine suffered a blown head gasket for the second time. Facing the prospect of repetitive, costly repairs, Troy opted to replace the combustion engine with an electric powertrain instead.


The Build: Simple and Cost-Effective

The primary goal for this build was simplicity and affordability, focusing on a vehicle suitable for low-speed, city-oriented driving. The total investment for parts was kept under $5,000. The mechanical transformation involved several key components:

  • Motor: A 72-volt DC motor from D&D Motor, priced at $929, provides 9 horsepower and 65 lb-ft of torque. It is connected to the original five-speed manual transmission via an adapter plate.
  • Controller: An $815 500-amp controller manages the power delivery.
  • Battery: The vehicle utilizes a 105-amp-hour lithium-iron-phosphate battery, typically used for golf carts, which is mounted where the original fuel tank was located.

Performance and Practicality

Because the original Suzuki lacked vacuum-assisted brakes, the conversion process was significantly simplified, removing the need for additional vacuum pumps. While the vehicle retains its original gearbox, the clutch is no longer required for operation.

Regarding performance, the owner notes that the vehicle achieves a top speed of approximately 50 mph—comparable to the original gas engine's capabilities. With a charging time of about five hours via a standard 120V outlet, the current setup provides a functional range of 20 to 30 miles.


«It is one of the simplest and cheapest conversions out there, and that was on purpose. He just wanted to drive the car at low speeds and around town, and it fulfills these requirements perfectly.»

This project highlights a broader trend among automotive enthusiasts. By utilizing accessible, off-the-shelf components, owners of older, unreliable vehicles are finding new life for their classic cars. While the current battery capacity limits the vehicle to short-range tasks, the modular nature of the design allows for easy upgrades, demonstrating that an electric future is accessible to those willing to put in the effort.