There has been so much press about plug-in hybrids, PHEVs, that one would think that rechargeable cars with a gasoline range-extender are readily purchasable at WalMart. That's what i thought. There are none commercially available today and experts believe that dealerships will not offer affordable, factory-produced, reliable, and serviceable PHEVs for several years.
It is possible to convert a hybrid into a plug-in hybrid by adding a battery pack and a control system. The cost varies between $6000 and $24000, depending on your do-it-yourself abilities and the battery pack selected. After-market battery choices include old-fashioned lead acid, lithium-ion, and nickel-metal hydride.
Surprisingly, car manufacturers have been lenient on converted-car owners, apparently preferring to support grassroots clean technology and not further tarnish their own big iron reputation. Toyota, Mercury, and Ford manufacturer hybrids amenable to PHEV retrofit. The Honda hybrid cannot be easily converted because the engine and motor always run at the same time.
The CalCars web site web site describes the retrofit process in some detail and lists some vendors who will undertake the task. A photo of a CalCar battery pack is above. Plug-In Conversions Corp here in San Diego will soon retrofit Nilar NiMH batteries and the EAA-PHEV open source control system. They are taking orders now and will being conversions in early 2008. With installation requiring only one day, its faster than having your transmission rebuilt at Pep Boys.
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