Turning My Ford Focus Into an Electric Car A Complete Guide

Converting your Ford Focus into an electric car is a cost-effective, eco-friendly upgrade that combines DIY innovation with modern EV technology. This guide walks you through essential steps—from selecting the right motor and battery system to ensuring safety and performance—so you can transform your gas-powered Focus into a reliable electric vehicle. With careful planning and the right components, you can achieve a seamless EV conversion and enjoy lower emissions, reduced fuel costs, and a truly custom ride.

Key Takeaways

• Assess compatibility: Verify your Ford Focus model supports EV conversion before starting.
• Choose quality components: Invest in reliable batteries, motor, and controller for performance.
• Plan your budget: Expect $8k–$15k for parts and professional installation costs.
• Prioritize safety: Follow EV wiring standards and use proper insulation techniques.
• Check local laws: Ensure converted vehicle meets registration and road legality requirements.
• Optimize weight distribution: Place batteries strategically to maintain handling and balance.

Why I Decided to Turn My Ford Focus Into an Electric Car

I never thought I’d be the type of person to retrofit a car. My Ford Focus, a trusty 2013 hatchback, had been with me through road trips, grocery runs, and even a cross-country move. But as gas prices climbed and my environmental guilt grew, I started wondering: Could I turn my Ford Focus into an electric car? The idea felt wild at first—like trying to turn a flip phone into a smartphone. But the more I researched, the more it made sense. I didn’t want to buy a new EV (too expensive), and I didn’t want to scrap my reliable Focus (too wasteful). Retrofitting seemed like the perfect middle ground.

After months of planning, late-night YouTube binges, and countless calls to mechanics, I took the plunge. This guide is everything I wish I knew before starting. Whether you’re curious about the process, worried about costs, or just love the idea of giving your old car a new life, I’ll walk you through the realities—both the highs and the headaches. Spoiler: It’s not as simple as swapping an engine, but it’s absolutely doable.

Understanding the Basics of EV Conversions

What Is an EV Conversion?

An EV conversion means replacing your car’s internal combustion engine (ICE) with an electric motor and battery pack. Think of it like a heart transplant, but for a car. Instead of burning gas, your vehicle runs on electricity stored in batteries and powered by a motor. The rest—steering, brakes, suspension—stays mostly the same. For my Ford Focus, this meant removing the 2.0L engine, fuel tank, and exhaust system, then installing a motor, controller, batteries, and charging system.

Key Components You’ll Need

Here’s the “ingredients list” for your EV conversion. I learned the hard way that skipping any of these can lead to costly mistakes:

• Electric motor: The “new engine.” I chose a 100kW AC motor (about 134 horsepower) to match my Focus’s original power.
• Battery pack: Stores energy. I used lithium-ion (LiFePO4) for safety and longevity.
• Motor controller: Manages power flow from batteries to motor. A critical “brain” component.
• DC-DC converter: Powers 12V accessories (lights, radio) from the main battery pack.
• Charging port: Lets you plug in. I installed a CCS combo port for Level 2 and DC fast charging.
• Cooling system: Batteries and motors get hot. A radiator and coolant pump are non-negotiable.

Pro tip: Buy components from reputable EV conversion suppliers (e.g., EV West, Thunderstruck Motors). I tried a “budget” motor from eBay and had to replace it within 3 months.

Is Your Ford Focus a Good Conversion Candidate?

Not all cars are ideal for conversions. My Focus was a great fit because:

• Lightweight: At 3,000 lbs, it’s easy to offset the added battery weight.
• Simple drivetrain: Front-wheel drive with a transaxle made motor mounting straightforward.
• Ample space: The engine bay and rear cargo area could fit batteries without major modifications.

But be honest with yourself: If your Focus has rust, frame damage, or a failing transmission, fix those issues first. Retrofitting a car with existing problems is like building a house on a cracked foundation.

Planning Your Conversion: Costs, Tools, and Timeline

How Much Does It Cost?

The million-dollar question (or in my case, the $15,000 question). Here’s a breakdown of my actual costs:

Component	Cost	Notes
Electric motor + controller	$6,200	AC motor with regenerative braking
Battery pack (36 kWh)	$7,000	LiFePO4, 200 miles range
Charging system	$1,200	DC-DC converter, CCS port, charger
Cooling system	$600	Radiator, pump, hoses
Miscellaneous (wiring, mounts, tools)	$1,500	Don’t skimp here—quality matters
Total	$16,500	Before tax and labor

Wait, what about labor? I did the work myself, but if you hire a shop, add $3,000–$8,000. Some states offer EV conversion tax credits—check yours!

Tools and Skills You’ll Need

You don’t need to be an engineer, but you’ll need:

• Basic mechanical skills: Wrenching, welding, and electrical work.
• Tools: Socket set, torque wrench, multimeter, angle grinder, and a good drill.
• Software: A laptop for programming the motor controller (I used Zilla software).

I’m a DIYer, but I’m not a pro welder. I paid a local shop $300 to fabricate custom motor mounts. Know your limits.

Timeline: How Long Does It Take?

My conversion took 4 months working 20 hours/week. Here’s the rough schedule:

• Weeks 1–2: Research, order parts, and strip the engine bay.
• Weeks 3–6: Install motor, batteries, and cooling system.
• Weeks 7–10: Wire the controller, charging system, and safety circuits.
• Weeks 11–16: Test, troubleshoot, and finalize.

Unexpected delays are normal. My battery pack was backordered for 3 weeks, and I spent 2 days fixing a wiring short. Build in a 30% time buffer.

Step-by-Step: Converting the Ford Focus

Step 1: Remove the ICE Components

Start by draining all fluids (oil, coolant, transmission fluid). Then remove:

• Engine and transmission
• Fuel tank and lines
• Exhaust system
• Radiator (save the hoses!)

Tip: Label every bolt and hose. I took 200+ photos during disassembly. A missing bolt can mean hours of hunting.

Step 2: Install the Electric Motor and Controller

Mount the motor to the transaxle using a custom adapter plate. My AC motor bolted directly to the Focus’s original transmission. The controller went in the engine bay, mounted to the firewall. Use rubber isolators to reduce vibration.

Safety check: Ensure all high-voltage connections are insulated and secured. I used heat-shrink tubing and zip ties—no loose wires!

Step 3: Build and Install the Battery Pack

This was the most nerve-wracking part. I built a 36 kWh pack using 96 LiFePO4 cells (4.8V each). The pack split into two modules:

• Front module: 18 kWh under the hood.
• Rear module: 18 kWh in the cargo area (replacing the spare tire well).

Pro tip: Use a battery management system (BMS) to monitor cell health. My BMS saved me from a thermal runaway when a cell started overheating.

Step 4: Wire the Charging and Cooling Systems

Install the DC-DC converter to power the 12V system. The charging port went where the gas cap used to be. For cooling:

• Run coolant hoses from the motor to a radiator (mounted in the front bumper).
• Use a thermostat to control the coolant pump.

I reused the original Focus radiator for the cooling loop—it fit perfectly!

Step 5: Test and Calibrate

Before driving, test every system:

• Check for voltage leaks with a multimeter.
• Program the motor controller (set max current, regen strength, etc.).
• Test the BMS and emergency disconnect.

My first test drive was terrifying. The car lurched forward at 30 mph—I’d misprogrammed the throttle response. A 20-minute software tweak fixed it.

Challenges and Lessons Learned

Weight Distribution: A Hidden Headache

Batteries are heavy. My 600-lb pack shifted the Focus’s center of gravity. The rear sagged, and the front end felt light. I fixed it by:

• Adding coilovers to the rear suspension.
• Relocating some battery cells forward.

Lesson: Balance is critical. A poorly distributed pack can ruin handling and tire wear.

Regen Braking: Not as Simple as It Seems

Regenerative braking (recapturing energy when slowing down) is a major EV perk. But it requires:

• A compatible motor controller.
• Integration with the hydraulic brake system.

I used a “blended” system: Regen kicks in first, then hydraulic brakes take over. It took trial and error to get the feel right—my first attempt felt like the brakes were “grabby.”

Charging Infrastructure: The Real-World Test

My Focus has a 200-mile range, which is great… until I need to charge. Public CCS chargers are rare in my area. I ended up:

• Installing a Level 2 charger at home ($600).
• Planning trips around charging stops.

EV conversions are not plug-and-play. You’ll need to adapt your driving habits.

Unexpected Costs and Setbacks

Even with a budget, surprises happen. Mine included:

• A faulty BMS ($200).
• Custom wiring harnesses ($400).
• Repainting the battery enclosure ($150).

Always keep a 15% “oh sh*t” fund.

Living With My Electric Ford Focus

Daily Driving: The Good and the Bad

After 6 months, here’s my honest take:

The Good:

• Silent and smooth: No engine noise, no gear shifts. It’s eerily quiet.
• Low maintenance: No oil changes, spark plugs, or exhaust work. I spend $50/year on maintenance.
• Instant torque: 0–60 mph in 7 seconds—faster than the original Focus!

The Bad:

• Range anxiety: 200 miles is enough for daily use, but I can’t take spontaneous road trips.
• Charging time: Level 2 charging takes 6–8 hours. Not ideal for last-minute plans.
• Weight: The car handles like a tank in snow. Winter driving is… cautious.

Cost Savings: Is It Worth It?

My Focus now costs $0.03 per mile (vs. $0.12 per mile for gas). Over 10 years, I’ll save ~$15,000 on fuel. But remember: The upfront cost is high. If you drive less than 10,000 miles/year, a new EV might be cheaper long-term.

Environmental Impact

My conversion reduced CO2 emissions by ~4.6 tons/year (based on U.S. grid averages). Plus, I kept a working car out of the junkyard. Win-win!

Community and Support

Join EV conversion forums (e.g., Endless Sphere, DIY Electric Car). Other converters saved me from countless mistakes. One guy in Texas helped me troubleshoot a controller issue via Zoom!

Final Thoughts: Should You Convert Your Ford Focus?

Turning my Ford Focus into an electric car was one of the most rewarding projects I’ve ever done. It’s not cheap, easy, or fast—but it’s doable. If you’re considering it, ask yourself:

• Do I enjoy hands-on projects? (This isn’t for passive learners.)
• Can I handle setbacks? (There will be many.)
• Is my car worth saving? (A rusty Focus isn’t a good candidate.)

For me, the answer was yes. My electric Focus isn’t perfect, but it’s mine—a unique blend of old-school reliability and modern tech. It turns heads, saves money, and makes me smile every time I plug it in.

To anyone thinking about this journey: Start small. Research. Talk to other converters. And remember—every expert was once a beginner. Your electric Ford Focus could be just a few wrenches away.

Frequently Asked Questions

Can I convert my Ford Focus into an electric car?

Yes, you can convert your Ford Focus into an electric car using a DIY EV conversion kit or by hiring a professional conversion shop. This process replaces the internal combustion engine with an electric motor, battery pack, and supporting electronics.

How much does it cost to turn a Ford Focus into an electric car?

The cost of converting a Ford Focus into an electric car typically ranges from $8,000 to $15,000, depending on battery size, motor type, and labor. Higher-capacity batteries for longer range will increase the overall price.

What is the range of a converted electric Ford Focus?

A converted electric Ford Focus can achieve a range of 80–150 miles per charge, depending on battery capacity (e.g., 20–40 kWh) and driving conditions. Upgrading to lithium-ion batteries can improve range and performance.

Do I need special tools or skills to convert my Ford Focus to electric?

Basic mechanical skills and common tools are required for a DIY conversion, but specialized knowledge of high-voltage systems is crucial for safety. Many opt for professional help or use pre-designed Ford Focus EV conversion kits to simplify the process.

Is converting a Ford Focus to electric legal and street-legal?

Yes, as long as the conversion meets local and federal safety and emissions regulations, including proper battery containment and lighting systems. Check with your DMV or transport authority to ensure compliance in your area.

What are the benefits of turning my Ford Focus into an electric car?

Converting your Ford Focus to electric reduces fuel costs, lowers emissions, and offers a quieter, smoother driving experience. It also extends the life of your vehicle while supporting sustainable transportation through EV conversion.