I haven’t commented further here from the exchanges three weeks ago, or updated my project thread until I had something objective to share regarding the formal and bureaucratic side of the conversion process. I’m pleased to say that I do indeed have an update, but before sharing, I just wanted to comment on the earlier suggestions that my car would/should be classed as radically altered by the authorities.
Yes, I changed part of my boot floor (less than a quarter of the total surface area) to make way for a reinforced stainless steel battery box. Yes, I added in strengthening. Yes, I had a professional fabricator do the job, Yes, I have followed the DVSA’s rules when it comes to finishes of the build. Let’s be honest, every single car in the project section of this forum has had the chassis modified during a conversion. The odd hole drilled here or there or use of a grinder could still constitute a modification to the chassis if we’re to interpret ‘the rules’ in black and white terms. It therefore highlights that it is impossible to complete EV conversion without some form of chassis modification however minor that may be.
If you’re new to this thread, you can read my previous posts on the experiences with the DVLA.
They are here:
viewtopic.php?f=9&t=543#p6670
And here:
viewtopic.php?f=9&t=543&start=50#p17322
And here:
viewtopic.php?f=9&t=543&start=75#p21272
The update:
The inspector visited on 18th Jan. He was very professional and friendly and said that most of his work related to inspections of cars pre 1980 (presumably for applications to historic classification). He had no idea what he was to inspect, just had the reg, make and model - that was it! I asked him what would have flagged my car for inspection. He said it really does depend on whose desk it lands on at the DVLA. He also said that in all probability the DVLA are just checking that the car is what I say it is from the forms, letters and pictures previously provided.
Before he got started, I offered to give an overview of the Boxster of which he accepted. I spent 5 or so minutes walking him around the vehicle, explaining the technical elements of the conversion from charge port right through to drive train and batteries. I explained that a local professional fabricator had supported the build and done the motor mount system and battery box installation.
In total the inspector spent about 30 minutes going over the car. Surprisingly I was asked to remove the engine bay covers as it’s quite fiddly and time consuming on the Boxster. He took LOTS of pictures inside the engine bay and underneath the rear of the car. He also took pictures of the three VIN locations. He was using two separate devices presumably for backup purposes.
He advised that his report would be submitted to the DVLA on the same day and that it would take them about a week to come back to me. I asked whether he was working to the aforementioned points system and he said that he was. I asked if I have anything to worry about, he wasn’t overly specific but he did say the DVLA and if required DVSA, will judge each case on its merits if need be – and they’re looking to find botched and dangerous workmanship rather than stop folk performing professional bona fide work. Certainly not black and white, however it does suggest there’s room in ‘the system’ for a pragmatic approach by the authorities (instead of; chassis mods are prohibited, end of). He also said that IF the DVLA determine that they’d like the DVSA to complete an IVA, that doesn’t necessarily mean the car would be considered radically altered.
If you’ve come this far reading my story, you’ll have noticed that during interactions with the DVLA over the past year, they moved the goalposts several times. For example, when they wrote to me last March advising that the new V5 would be issued upon providing XY and Z, I was then told that actually XY and Z was insufficient and would be asked to jump through further hoops. Unbelievably the bureaucratic theme continued even after the inspection, and on the 27th January I received an email asking that I complete a V10 application for vehicle tax. They sent me a letter last March advising that I need to tax the car before proceeding with the application, so why are they now asking again?! Frustrating, but was this a light at the end of the tunnel?
The good news is that it was indeed a light and it formed the final part of my tortuous 12 months dealing with the DVLA. The new V5 has been issued and fuel type classified as electricity. Hurrah!
I would like to thank everyone for commenting in this thread particularly Ken for sharing his knowledge and moral support.
For those going through this in future, my only advice would be to keep a very close eye on the DVLA and their inconsistent processes. They clearly do not have a defined workflow for EV conversions and are therefore processing applications on an ad hoc basis. In addition, the SGS inspection is little more than what the local DVLA local office used to do. However, it’s notable that the inspector was very interested to photograph how the HV cables were clipped – every 100mm and using rubber lined stainless clips. I’ll update my project thread with what I used.
It would seem that as long as the DVLA and SGS inspection do not deem your build a basket case, you will not be asked to undergo an IVA or indeed go down the radically altered vehicle route.
Feel free to shout if you have any further questions. I’m off for a celebratory beer.
