The 2008 Ranger is our chosen truck, and the conversion of the vehicle produces a rather impressive EV truck.  Many people have contacted us and asked for information on converting their own Ford Rangers.  We have decided to publish images of the conversion process to assist others in converting their cars, and to further the use of EV's in the United States.
    Our conversion process is very complex due to fact that the vehicles we convert belong to our customers.  So, a great deal of care is taken to make sure that the vehicle is delivered in its original condition.  The process need not be as complex for the backyard conversion.
    The truck in this conversion series is a 2008 Ford Ranger in Dark Shadow Gray.  This has by far been the most popular color of the vehicle, and has been chosen in over 50 percent of the sales.
    Enjoy the images, we hope that they help you in your quest.  If you would like more photos of the complete process contact one of our dealers and they would be happy to share those with you.  Videos are also available.  Conversion kits will be posted along with the prices later this month.  The conversion kits can be ordered with or without the adaptor plates, motor mount, and pulley assembly.

    An incoming vehicle is inspected several times.  Once by the supplier upon arrival, and then again by one of our receiving technicians.  It is then cleaned up and checked again by the convertors!  Dings do happen, you just have to be sure that you own the ones you did and didn't inherit any.  Great care is taken to ensure the integrity of the paint and body of any vehicle we process.

    A quick walk around of the vehicle to check for dings, dents, or other flaws before the process begins.

     Nothing wrong back here either. 

    The inside checks out.  I have the same slip covers on the sofa and arm chair at my house.

    The engine compartment is even examined.  Certain elements remain after the conversion.  The battery in the upper right, the radiator (because of the condensor coil for air conditioning) power assist for brakes and steering, alternator, and of course the compressor.

    It is always a good idea to verify that what you are converting is a sound platform, so the trucks are put on a dyno to make sure that the drive train integrity is there.  

    In 2007 we just sent a guy out for a test drive, if he didn't come back we knew there was a problem.  This way seems to be a lot more efficient.

    This dyno is four wheel drive capable.  You can also tell that these guys know what they are doing.  Heavy duty nylon restraints are a good idea.  I can tell you from experience that bungee cords are a bad idea, but they do raise the level of excitement in the shop.

    The dyno readings really are just an insurance policy against problems after the conversion.  A good technician will notice anything different in the readings from one vehicle to the next.  If something is seen, you send the vehicle back.  Don't convert a flawed vehicle.

    Removing fuel from the tank is a good idea prior to removing it from the frame.

    Tail gate off in preparation of bed removal.

    Tail gate set aside and ready to go in to storage.

    A little tape protection around the bolts ensures no chips in the paint during the bed removal.

    Be aware of the stabilizing ribs under the bed.  Remove these after the bed bolts.  Also, tail lights don't work by magic.

    Tail light electrical harness location.  Note the tape to protect the paint on the bed during the removal of the bolt and clamp.  A little extra time means a lot in the final product quality.

    The external fuel fill tube connection.  This will be replaced with a charge point plug.

    Bed removed, fill tube exposed.  This tube will be replaced with a power line from the LiFePO4 charger.  The umbilical cord to the middle east has been severed.

    Bed off, and looking like a baby Mack.  I think the rims still look cool!  Ford makes one nice looking truck!

    The bed is ready to go in to storage while the conversion is completed.  I was looking back through the pictures......shoot....my kitchen is not as clean as this work area.  I should work on that...sometime.

     A little protective tape goes a long way to ensure that you finish remains perfect.  These guys are good!

    Hood off and ready for ICE removal.

    Hood off and ready to stow.

    The fuel and exhaust systems have been removed.  The fuel tank itself is an engineering marvel, but we won't need it.

    Next time someone in your circle of acquaintances uses the term "Doohickie" to identify an unknown item just whip out this picture and tell them that this is a "Doohickie".  Of course this is a Ford Doohickie but it should break them of the use of the term.  Just another public service from your friends at LionEV.

    The fuel and exhaust are now out of the frame.  You can clearly see why we say that trucks are the easiest vehicles to convert.  There is a tremendous amount of room for battery packs under the bed.  Lead Acid batteries would add over half a ton to this truck and mess with its suspension design.  The lithiums are less than half that weight for double the energy.

    As any mechanic will tell you, taking the bolts and hardware off of a new vehicle is SWEET!  Try this on a truck that has been on the road for a few years and you are going to need to use a lot of persuasion.  This is usually in the form of a large mallet, a torch, swear words and some damaged knuckles.  

    Hundreds of conversions are done every year without the use of a lift.  We highly recommend that you rent one just for the occassion.  It makes life a lot easier, and you go home a lot cleaner.

    There is a hefty market for new motors, so care is taken to keep it in like new condition.  Older motors are also very marketable, so the care taken after removal can make a big difference in what you will get for it later.

    Motor out.  Some of the components of the engine assembly will be installed back in the truck.  Once this is done the motor will be put on a pallet and wrapped for shipment.

    Ice components set aside.  All of the items you remove from you vehicle are marketable, though the fuel tank itself is a bit hard to unload.  For most dumps to take it you will have to cut it in half.