This thesis follows the design of a customized battery pack solution for EV conversion. The design focuses on the Toyota Land Cruiser 70 Extended model, a modified 7-seater for use in safaris and tours.

The aim of this research is to analyze, review, and to design a customized battery solution for the EV conversion of the Land Cruiser EV conversions that are currently being built.

he methodology for this research follows the analysis of the current EV conversion systems, their power and range requirements, as well as analysis of the battery configurations currently in use by the same systems. Additionally, the physical available space for the batteries, including their location and the weight of the battery packs is also considered.

These data are then implemented in the design of a novel battery pack system with various capacities and configurations, depending on the power demand and range requirements of the EV conversions being done.

The results of this research show that an improvement in overall battery capacity, which translates to higher range, is possible, as well as providing flexible configurations of various different capacities based on the cost constraints and performance requirements of the overall system. Additionally, a 12v Auxiliary battery pack design is also presented, which replaces the 12v Lead-acid battery being used currently, for a higher capacity and longer life for the same.