Having done three e9 EV conversions now I think I have a perspective.
It isn't for everyone, nor for every car. No one should take a CSL or a nice CSi and convert it. But my USA automatic was a prime candidate. I was never going to leave it stock. I initially engaged sfDon to help with a 3.5 injected 5 speed build. Perhaps that wouldn't have changed the character of the car as much as doing the EV conversion but let's not kid ourselves -- it is still a big deviation from stock and not cheap to accomplish well. In the end I would've had just a another resto modded e9. Not that there's anything wrong with them -- they're great. It's just that there are hundreds already just like it. Instead, I opted for a project that caused me to learn a lot of stuff I found interesting and allowed me the freedom to create something more unique. And cost me a lot more time and money. I'm not saying it is better in all respects but I like it.
The heaviest one we've done (my son-in-law's) weighs 3,500 pounds. That's with 80kwh (15 Tesla Model S battery modules) and a Tesla Model S large drive unit. Don't even try to floor it in sport mode at under 30 mph as it just lights up the tires. It has VW rack and pinion steering, Ground Control coilovers, and big Wilwood brakes. I don't think anyone who drives it would call it non-enthusiastic. Certainly everyone I've ever let drive or ride in it has come away amazed. It even handles curves well. Granted, it is 300 pounds heavier than stock but it more than compensates for that with boundless torque and power.
The second one (mine) has 14 modules and a Model S small rear drive unit. *Only* 298 horsepower but lighter by 200 pounds due to stock suspension and brakes, one less battery, and some other savings. Still fun.
The third one just came back from paint and was only driven for shake down. It has 16 modules and large sport drive unit with a different VCU, electric rack and pinion, coilovers, big brakes, a Quaife locking diff, etc. It might end up slightly over 3,500 pounds but should be insane when done. The owner has track aspirations for it.
I'm a snob for range and power so I'm not particularly enamored by the 2002 with only 33kwh and a 178 hp Tesla front drive unit but it is a clean build. Besides, everyone lies about range and weight. I doubt that car weighs 2400 pounds. The i3 battery alone weighs 256 kg (563 pounds) and the front drive unit is 90kg (200 pounds). Add the OBC, DC/DC, BMS, A/C, etc. and it would have to weigh more than the original 4 banger, trans and diff so that takes the original 2,250 pound car higher I suspect. It also isn't a 400 volt battery -- it is 355-360 volts so believe what you will. Maybe a rounding error. As for 200 km (120 mile) range with only 33kwh, I'm suspect there too. My Fiat 500e has 24kwh, weighs 2,980 pounds and gets 90 mile range. Less efficient aero, tires, etc on the 2002. We're getting about 200 miles from 80kwh when Tesla gets 235 miles from 72kwh because these aftermarket conversions are never as efficient as OEM. The other conversion that kept the trans with 28kwh and 63 hp motors is much worse in power, range and efficiency. At low power and limited range they're just hobby cars and aren't interesting but with enough power and range the equation changes.
The cost of doing these is more than most of you would want to spend and I'm not sure anyone should ever expect to recoup their investment and one can certainly argue about the soul of car being lost. But the end results are personalized and special and a lot more fun than you think.
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