Mechanical Feasibility and Structural Evaluation of an Opel Vectra 1998 Chassis during Electric Vehicle Conversion
Elkelawy, M., Saeed, A., Atta, Z., Sayed, M., Hamouda, M., Almasri, A., Talaat, H., Seleem, H. (2025). Mechanical Feasibility and Structural Evaluation of an Opel Vectra 1998 Chassis during Electric Vehicle Conversion. EKB Journal Management System, 2(2), 319-333. doi: 10.21608/pesj.2025.389924.1031
Medhat Elkelawy; Ahmed Mohammed Saeed; Zeiad Ayman Atta; Mustafa Mamdouh Sayed; Mohamed Abdalla Hamouda; Ahmed Mohamed Almasri; Hazem Mohammed Talaat; Hussein Eltaibee Seleem. "Mechanical Feasibility and Structural Evaluation of an Opel Vectra 1998 Chassis during Electric Vehicle Conversion". EKB Journal Management System, 2, 2, 2025, 319-333. doi: 10.21608/pesj.2025.389924.1031
Elkelawy, M., Saeed, A., Atta, Z., Sayed, M., Hamouda, M., Almasri, A., Talaat, H., Seleem, H. (2025). 'Mechanical Feasibility and Structural Evaluation of an Opel Vectra 1998 Chassis during Electric Vehicle Conversion', EKB Journal Management System, 2(2), pp. 319-333. doi: 10.21608/pesj.2025.389924.1031
Elkelawy, M., Saeed, A., Atta, Z., Sayed, M., Hamouda, M., Almasri, A., Talaat, H., Seleem, H. Mechanical Feasibility and Structural Evaluation of an Opel Vectra 1998 Chassis during Electric Vehicle Conversion. EKB Journal Management System, 2025; 2(2): 319-333. doi: 10.21608/pesj.2025.389924.1031

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

Pharos Engineering Science Journal
Volume 2, Issue 2, December 2025, Pages 319-333    PDF (1.3 M)
Document Type: Research articles
DOI: 10.21608/pesj.2025.389924.1031
Authors
Medhat Elkelawy* 1; Ahmed Mohammed Saeed2; Zeiad Ayman Atta3; Mustafa Mamdouh Sayed4; Mohamed Abdalla Hamouda3; Ahmed Mohamed Almasri3; Hazem Mohammed Talaat5; Hussein Eltaibee Seleem6
1Mechanical engineering department, Faculty of Engineering, Pharos University in Alexandria, Alexandria, Egypt Department of Mechanical Power Engineering, Faculty of Engineering, Tanta University, Tanta, Egypt
2Mechanical department, Faculty of engineering, Pharos University in Alexandria (PUA), Alexandria, Egypt
3Mechanical engineering department, Faculty of Engineering, Pharos University in Alexandria, Alexandria, Egypt
4Mechanical engineering department, Faculty of Engineering, Pharos University in Alexandria, Alexandria, Egypt – Email: 202100703@pua.edu.eg
5Mechanical designers, Tanta, Egypt, Phone: 01006564959, 01114313971, Email: haztal313@gmail.com
6Electronics and Communications Engineering, Faculty of Engineering, Tanta University
Abstract
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.
Keywords
Opel Vectra retrofit (OVR); ICE-to-EV conversion; Lithium-ion battery integration (LIB); Aerodynamic drag optimization (ADO); Sustainable urban mobility (SUM)
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