A Budget EV Swap With Big Ambitions
Electric car conversions are often seen as luxury projects, the kind reserved for classic showpieces and deep-pocketed hobbyists. But one DIY builder has turned that perception upside down. A neglected 1962 Mercury Comet station wagon, once a dusty, non-running relic, has been reborn as a fully electric daily driver using salvaged parts from a wrecked Nissan Leaf. The entire conversion came in under $6,000, relying on resourcefulness rather than rare parts or big funding.
The idea stems from a growing opportunity in the used EV market. Early Leafs, Bolts, and similar models are now cheap, plentiful, and mechanically simple, making them ideal donors. Chronicled on the This Old Jalopy YouTube channel, the Comet project documents a step-by-step transformation that blends mid-century style with 21st-century sustainability. The goal was to build a zero-emissions classic while maintaining its vintage character and proving that electrification doesn’t have to cost a fortune.
Old-School Wagon Meets Mass-Market EV Tech
The donor car, a 2014 Nissan Leaf, had crash damage but an intact high-voltage system—perfect for repurposing. For just $3,000, it provided the motor, inverter, charger, and its 24-kWh battery pack. To make those components function outside their original chassis, the builder added a Resolve EV controller for about $900, allowing seamless communication between the Leaf’s battery management system and its power electronics.
Installing the Leaf’s front-drive motor in the Comet’s rear required inventive fabrication. It now powers a custom De Dion rear axle supported by upgraded leaf springs, with shortened CV shafts to match the new layout. Up front, where the original gas engine once sat, the Leaf’s 48 battery modules are housed in a custom cradle, maintaining good weight balance and serviceability. Only a few modules were replaced, keeping the pack mostly original and cost-efficient.
Trial, Error, and a Surprisingly Stock Result
Like most EV conversions, the Comet project hit a few snags. Early tests revealed a no-drive condition traced to wiring mistakes, an inverted high-voltage line, and a faulty charger. Replacements and careful rewiring fixed the issues, after one brief mishap that sent the wheels spinning backward.
Finishing details tie the project together. The charging port now hides behind the factory fuel door, while the control unit sits discreetly in the glovebox. From the outside, the wagon looks original, belying its modern electric heart with an estimated range of about 78 miles – not much, but it should be usable within the city.
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