2000 Toyota Solara convertible with Leaf parts/Ioniq 5 modules
Posted: Fri Dec 12, 2025 7:20 pm
Hello, after buying my first new car in decades, a locked-down OEM EV, I caught the EV conversion bug. I've been doing the usual forum reading, github perusing, document downloading and youtube video watching and have started to convert another car I already own. I am an embedded systems designer (software + firmware + hardware) and a big supporter of open-source. I'm in awe of what you all have accomplished over the years and I hope that I will be able to contribute in some small way to the body of knowledge and designs you have created.
My big problem is that I live on the side of a hill without a garage or even level parking area so I am extremely challenged in the physical fabrication parts of conversions. Plus I'm not particularly experienced with wrenching or metal fabrication. But I'm an enthusiastic learner, have joined my local makerspace with a metal shop and am looking for cheap garage space. I have also been extremely fortunate to have met two wonderful people near me also doing conversions. I'm helping them out with electrical/software stuff and one of them has been able to help with the removal of the engine and we're going to get the gas tank out this coming weekend.
I was also lucky enough to get to part-out a 2017 Leaf S and ended up with the motor stack and complete set of electronics including the main wiring harnesses. One of my new friends got an Ioniq 5 battery pack and I bought half the modules from him for a ~38 kWh pack. I'm not sure yet which direction I will go for control of the car. I would like to see if I can make the EPS motor, brake booster and ABS module fit in the Solara but won't know that until I can get the dashboard removed. If I can fit those then I might try to re-use the Leaf VCM since it knows the dance between all those systems. I also want to re-use the HVAC controller with PTC and AC compressor fitted to the Solara's HVAC box. One thing I have learned so far is that reality often clashes with my ideas when I get into the details. So it could be that I will end up installing pumps for the existing brake system and hydraulic power steering. In that case I will use Zombieverter. I plan to design my own LCD based dashboard and re-use the Leaf's non-networked radio since it has bluetooth to connect with a phone.
Aside from the fun of the EV conversion itself I am really interested in the embedded systems aspect of conversions and would like to design electronics and write code in this space. As with all my personal projects of any general interest everything I do will be pushed to my github with open-source licensing.
I originally wrote about this project on the DIY Electric Car forum because I wasn't immediately using Openinverter or Zombieverter and didn't know if my project would fit here. But that forum seems to be in trouble so I hope you'll have me. I'll write about my progress and the stuff I design along the way. And if I can I'll help others and with the wiki.
My big problem is that I live on the side of a hill without a garage or even level parking area so I am extremely challenged in the physical fabrication parts of conversions. Plus I'm not particularly experienced with wrenching or metal fabrication. But I'm an enthusiastic learner, have joined my local makerspace with a metal shop and am looking for cheap garage space. I have also been extremely fortunate to have met two wonderful people near me also doing conversions. I'm helping them out with electrical/software stuff and one of them has been able to help with the removal of the engine and we're going to get the gas tank out this coming weekend.
I was also lucky enough to get to part-out a 2017 Leaf S and ended up with the motor stack and complete set of electronics including the main wiring harnesses. One of my new friends got an Ioniq 5 battery pack and I bought half the modules from him for a ~38 kWh pack. I'm not sure yet which direction I will go for control of the car. I would like to see if I can make the EPS motor, brake booster and ABS module fit in the Solara but won't know that until I can get the dashboard removed. If I can fit those then I might try to re-use the Leaf VCM since it knows the dance between all those systems. I also want to re-use the HVAC controller with PTC and AC compressor fitted to the Solara's HVAC box. One thing I have learned so far is that reality often clashes with my ideas when I get into the details. So it could be that I will end up installing pumps for the existing brake system and hydraulic power steering. In that case I will use Zombieverter. I plan to design my own LCD based dashboard and re-use the Leaf's non-networked radio since it has bluetooth to connect with a phone.
Aside from the fun of the EV conversion itself I am really interested in the embedded systems aspect of conversions and would like to design electronics and write code in this space. As with all my personal projects of any general interest everything I do will be pushed to my github with open-source licensing.
I originally wrote about this project on the DIY Electric Car forum because I wasn't immediately using Openinverter or Zombieverter and didn't know if my project would fit here. But that forum seems to be in trouble so I hope you'll have me. I'll write about my progress and the stuff I design along the way. And if I can I'll help others and with the wiki.