Mechanical Feasibility and Structural Evaluation of an Opel Vectra 1998 Chassis during Electric Vehicle Conversion

This study develops a replicable framework for converting a 1998 Opel Vectra into a fully electric vehicle (EV), combining mechanical retrofitting with dynamic performance optimization. The methodology systematically replaces internal combustion engine (ICE) components with a 96V AC brushless DC motor (15 kW peak) and 60-kWh Li-ion battery pack, achieving a total mass of 1,670 kg. Power demand analysis shows a 54% increase to 14.24 kW at 120 km/h compared to an 800 kg baseline, with aerodynamic drag contributing 83% of total resistance. Urban driving cycles yield 205 km range (293 Wh/km) at 30.2 km/h average speed, while a 15% tire pressure reduction is shown to degrade range by 18%. Structural reinforcements to the chassis and suspension accommodate the battery load, validated through finite element analysis (FEA) in Autodesk Inventor. The proposed design reduces conversion costs by 30% relative to commercial kits while maintaining OEM safety standards. These results demonstrate a balanced approach to EV retrofitting, prioritizing energy efficiency, structural integrity, and economic feasibility for sustainable urban mobility solutions.