In a small garage in Kerala, something remarkable happened over the course of three days. While major automakers invest billions in electric vehicle development, one innovative car enthusiast demonstrated that the green revolution might be more accessible than we think. Armed with determination, technical knowledge, and a modest budget of Rs. 2.4 lakh, he transformed his aging Hyundai Santro Xing into a fully functional electric vehicle. This homegrown conversion not only challenges our perception of what’s possible with existing vehicles but also raises important questions about the future of sustainable transportation in India. Electric Hyundai Santro “Gareebo ki Jaan” Coming Soon.
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The Man Behind the Electric Dream
Arunkumar (name changed for privacy) isn’t your typical mechanic or engineer. A 45-year-old IT professional by day, he’s been tinkering with automobiles since his college days. “Cars have always been my passion,” he told me when I visited his workshop in Kochi. “But as fuel prices kept rising and pollution became worse, I started wondering if there was a better way to keep my old faithful running.”
His “old faithful” is a 2008 Hyundai Santro Xing that had served him reliably for over 14 years. When the engine started showing signs of age, instead of scrapping the vehicle or spending heavily on repairs, Arunkumar saw an opportunity to experiment with something he’d been researching for years: electric conversion.
“Everyone talks about buying new electric cars, but what about the millions of perfectly good vehicles already on our roads? Their bodies and most components are still functional—it’s mainly the combustion engine that pollutes and eventually fails,” he explained, wiping grease from his hands as we spoke.
The Conversion Journey: Three Days of Transformation
Day One: Saying Goodbye to Petrol
The conversion process began with the removal of the Santro’s original petrol engine, fuel tank, exhaust system, and related components. “It was almost like performing surgery,” Arunkumar recalled. “You’re essentially removing the heart of the car to replace it with something completely different.”
The Santro’s compact engine bay presented challenges, requiring careful planning to accommodate the new electric components. By evening, the car was stripped of its internal combustion system, leaving an empty space ready for its electric rebirth.
“That first night, I almost had second thoughts,” he admitted. “Seeing my car gutted like that was a bit emotional. But there was no turning back.”
Day Two: Installing the Electric Heart
The second day involved mounting the electric motor and installing the battery pack. Arunkumar opted for a 15 kW brushless DC motor that delivers approximately 20 horsepower—less than the original petrol engine’s 63 hp but sufficient for city driving.
“The beauty of electric motors is their instant torque,” he explained. “Even though the peak power is lower, the car actually feels more responsive in stop-and-go traffic.”
The most challenging aspect was fitting the lithium-ion battery pack. Without access to sophisticated battery management systems used by commercial manufacturers, Arunkumar had to create a custom solution. He installed 16 lithium-ion batteries with a total capacity of 15 kWh, cleverly distributed between the front compartment and where the fuel tank once sat.
“Battery placement is crucial for weight distribution and safety,” he noted. “I wanted to maintain the car’s balance while ensuring the batteries wouldn’t be damaged in case of a minor collision.”
Day Three: Wiring, Programming, and First Drive
The final day involved connecting all electrical components, programming the controller, and integrating the system with the car’s existing 12V electrical network. This required extensive knowledge of automotive electronics—something Arunkumar had acquired through years of self-study and online courses.
“The controller is basically the brain of the system,” he explained while showing me the compact unit mounted near the motor. “It manages power flow, handles regenerative braking, and ensures everything operates safely.”
By late afternoon, the moment of truth arrived. With a mixture of nervousness and excitement, Arunkumar turned the key. There was no familiar engine sound—just a faint hum as the systems initialized, followed by silence. The dashboard lit up, indicating the car was ready to move.
“That first test drive around the block was unforgettable,” he reminisced, smiling broadly. “The silence, the smooth acceleration—it felt like I was driving the future.”
The Numbers That Matter: Cost, Range, and Performance
Breaking Down the Rs. 2.4 Lakh Investment
The total conversion cost of Rs. 2.4 lakh might seem substantial, but it’s significantly less than purchasing a new electric vehicle. Here’s how the budget was allocated:
- Electric motor and controller: Rs. 85,000
- Battery pack and BMS: Rs. 1,20,000
- Charger and electrical components: Rs. 25,000
- Miscellaneous hardware and accessories: Rs. 10,000
The labor was Arunkumar’s own contribution, saving considerable costs. “If I had paid a professional shop to do this conversion, the price would have easily doubled,” he estimated.
Real-World Range and Performance
After several months of daily use, Arunkumar reports that his electric Santro delivers approximately 120-130 kilometers of range on a full charge—sufficient for his daily commute and errands. The top speed is limited to 80 km/h, which he finds adequate for urban driving.
“I charge it overnight using a standard 15A socket, which takes about 6-7 hours for a full charge,” he explained. “The running cost is roughly Rs. 0.50 per kilometer, compared to around Rs. 5 per kilometer when it ran on petrol.”
The performance, while not matching the original specifications, comes with unexpected benefits. “The low-end torque makes it zippy in city traffic, and the absence of gear changes makes driving more relaxing,” he observed. “Plus, the car is now virtually maintenance-free—no oil changes, no filter replacements, no fuel system issues.”
Challenges and Limitations of DIY Electric Conversion
Despite the successful conversion, Arunkumar is candid about the limitations of his project.
“This isn’t something everyone should attempt,” he cautioned. “You need substantial electrical and mechanical knowledge, proper tools, and a deep understanding of safety protocols. One wrong connection could lead to catastrophic failure.”
Other challenges include:
Regulatory Hurdles
Getting the modified vehicle approved by transportation authorities proved challenging. Current regulations in India don’t clearly address aftermarket electric conversions.
“I had to convince the RTO that the modification was safe and environmentally beneficial,” Arunkumar said. “Eventually, they granted approval, but the process took months and required multiple inspections.”
Safety Considerations
Without the sophisticated safety systems of commercial EVs, DIY conversions carry inherent risks. Arunkumar addressed this by incorporating multiple redundant safety features, including:
- Thermal management for batteries
- Isolated electrical systems
- Emergency disconnect switches
- Robust fusing and circuit protection
“Safety was my primary concern throughout the project,” he emphasized. “I wouldn’t drive my family in this car if I wasn’t completely confident in its safety.”
Long-term Viability
While the conversion has been successful, questions remain about long-term reliability. Battery degradation, component availability, and technical support remain concerns.
“I’m essentially the manufacturer, service center, and warranty provider all rolled into one,” Arunkumar laughed. “If something goes wrong, there’s no dealer to call.”
The Broader Implications: Could This Be the Future?
Arunkumar’s Santro conversion raises fascinating questions about sustainable mobility in India. With millions of functional vehicles already on the road, could conversion rather than replacement offer a more resource-efficient path to electrification?
Environmental Considerations
Manufacturing new vehicles—even electric ones—requires significant resources and energy. By extending the life of existing vehicles through electric conversion, we might reduce the overall environmental footprint.
“The greenest car is the one that’s already built,” Arunkumar pointed out. “By converting rather than replacing, I’ve saved all the energy and materials that would have gone into manufacturing a new vehicle.”
Economic Opportunity
If streamlined and scaled, conversion services could create a new industry segment, generating jobs and technical expertise while making electric mobility more affordable.
Some startups in India are already exploring this opportunity. Companies like Electron Motors and GoGoA1 have begun offering conversion kits and services for popular models, though costs currently remain high due to low production volumes.
Policy Implications
For widespread adoption, clearer regulations and potential incentives would be necessary. Just as the government offers subsidies for new EV purchases, similar support for certified conversions could accelerate the transition to electric mobility.
“With proper standards and maybe some financial incentives, I believe conversions could play a significant role in India’s electric transition,” Arunkumar suggested. “Especially for commercial vehicles like taxis and delivery vans where the economics make even more sense.”
The Next Steps for Arunkumar’s Project
Encouraged by his success, Arunkumar is now documenting his conversion process to help others. He’s also planning improvements to his existing setup:
“I’m looking at more energy-dense batteries that could extend the range to 200 kilometers without adding weight,” he revealed. “I’m also experimenting with a more efficient motor controller that could improve performance and range.”
His garage has become something of a local attraction, with curious neighbors and automotive enthusiasts stopping by to see the electric Santro in action. Several have expressed interest in similar conversions for their vehicles.
“The interest is definitely there,” he noted. “People are fascinated by the idea of breathing new life into their old cars while also going green.”
A Glimpse of Grassroots Innovation
Arunkumar’s Santro conversion stands as a testament to individual ingenuity and the potential for grassroots innovation to contribute to larger environmental goals. While not without limitations, such projects demonstrate that the path to sustainable transportation need not rely solely on major manufacturers and brand-new vehicles.
As we navigate the complex challenges of climate change and resource scarcity, perhaps we should pay more attention to these garage innovators who remind us that sometimes, the most sustainable solution isn’t buying something new—it’s reimagining what we already have.
For now, the quiet hum of Arunkumar’s electric Santro as it glides through Kochi’s streets represents more than just one man’s project. It symbolizes the untapped potential of India’s existing vehicle fleet and the creative approaches that might help bridge the gap between our fossil-fueled present and an electric future.
As he parks the car and plugs it in for the night, Arunkumar reflects: “Every journey toward sustainability begins with a single step. This was mine. What’s yours going to be?”
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