Completely forgot I had a thread on here😅. Well even though the plans have changed slightly, I guess I'll pick up where I left off:
I am converting a 2001 2.5L Mercury Cougar to electric using a mix of parts from the Nissan Leaf, Tesla Model S, Toyota Prius, Ford Focus Electric, and Honda Civic Hybrid. The goal is to make a fun city car to rival the range and performance of my 2012 Ford Focus Electric (which is currently stripped out a bit in the back for fun), and eventually surpass it in both when I can get my hands on a battery pack over 60 kWh. Here's most of the parts I have or are currently planning to get:
Car: 2001 Mercury Cougar V6 - $450
Motor: 2011 Nissan Leaf (EM61) - $430
Inverter: 2011 Nissan Leaf Inverter with P and S (Paul Holmes) brainboard/ logic board. - (Inverter): $250, (P and S Brainboard): $340
Coupler: Brat Industries Nissan Leaf Coupler. Still need to take to machine shop and have the center piece of clutch plate pressed in. - $221
Adapter Plate: Will update when purchased.
Transmission: 2005 Ford Focus MTX-75. Plan to swap in the differential and ring gear from the Cougar MTX-75. - $258 (includes diff. and ring gear price)
Onboard Charger: 2014 Tesla Model S Onboard Charger (Gen 2, Part Number: 1014963-00-G) - $430
DCDC Converter: 2011 Nissan Leaf DCDC Converter - $250
Battery: 2012 Nissan Leaf 24 kWh Battery - $2,110 (from Battery Hookup)
BMS: For now, using the BMS/LBC that came with the battery pack. May eventually go to Orion BMS. - $ (refer to Battery)
Precharge Circuit: Reusing what came with Leaf battery
Charge Ports: Currently going to use the J1772 and Chademo that came with DCDC Converter, eventually switch to CCS. - $ (refer to DCDC Converter)
Battery Case: 2 Honda Civic Hybrid boxes (one can hold half the battery pack), but may just cut the Leaf case and use that instead. - $50 from picknpull
Vacuum Pump: Volvo Vacuum Pump. Also have the option of using the spare Focus Electric Vacuum pump I have. - $25
AC Compressor: Leaning towards my spare Ford Focus Electric compressor, or a Nissan Leaf compressor.
Power Steering: Update when bought, probably going to get the Opel Zafira B pump.
"Gas" Pedal: Toyota Prius Pedal - $15
Rotors: Drilled/Slotted Rotors, brake pads, and shims from eBay. - $244
CV Axles: Mercury Cougar 2.0L manual trans., still need to buy extension piece and bracket - $152
Suspension: Vogtland Lowering Springs, RockAuto Struts, Strut Bellows, Strut Mounts, Stabilizer Bar Endlinks, and polyurethane sway bar bushings. - $636