Introduction to Weight Reduction
Weight reduction works double time for an EV conversion, on one hand you are improving the handling, efficiency and speed of your conversion and on the other hand it is useful in making room under the GVWR for batteries and passengers. A lighter car takes less force to accelerate, has lower Rolling Resistance, is easier to stop in emergencies, handles better, has more potential for batteries and reduces the need for suspension and brake upgrades. Luckily the performance and racing driving sector provides plenty of tips and mods for ways to reduce weight in your conversion. Each converter will need to decide on whether or not each mod is suitable for their situation; A specialised one seater commuter will have different priorities from a family car. Some of these mods would be very expensive and/or difficult, it aims to be an inclusive list not a recommended list.

Possible Ways to Reduce Vehicle Mass:

• Removing any unnecessary items from the car; rubbish, drink bottles, even floor mats or car seat covers, anything that is not essential for driving.
• Remove all unnecessary remnants of the ICE system e.g. wiring, sensors etc.
• Removing the spare tyre and using run-flat tyres or Roadside Assistance in case of a puncture.
• Remove sound deadening material.
• Installing light weight racing seats/removing seats which aren't used (and their seatbelts and seatbelt mounts).
• Removal of the glass windows and replacement with Perspex
• Using lightweight alloy (magnesium or aluminium) wheels.
• Removing of non driving/safety components such as head-liners, Air conditioning, Radio etc.
• Replacement of body panels with aluminium, fibreglass or Carbon Fibre
• Drilling out holes from structures/components when it will not compromise its integrity (see Autospeed Article).

Sources:
torquecars.com
hondaclub.com