12:00 noon: The combustion engine is gone. A four-inch pin sticks out of the transmission shaft. Gadget and his crew are behind schedule because when taking out the old engine, they spilled a half-cup of antifreeze. They had to clean it up with absorbent pads and cat litter. It took 90 minutes.
Now they're trying to get the electric motor to mesh with the transmission pin. It won't cooperate. "It looks like they made the pin a little longer in this particular model," says Gadget.
2:15 p.m.: Gadget takes a hacksaw and begins cutting the half-inch-diameter pin. It's maddeningly slow. "I've got a power blade that could buzz this off in 10 seconds," he says.
Gadget has performed about a dozen conversions to date. In his shop, he can convert a car in four to five days. He charges about $20,000 a conversion. Batteries are included, which, at $6,000 to $7,000 a set, are considerably more than your average AA purchase, even at Costco. Twenty grand may seem like a big outlay, but just a couple of booths away is a fully electric minivan built by AC Propulsion that is priced at nearly $60,000. One aisle over is a sporty car called the Electrum Spyder, also for $60,000.
Still, the real payoff comes at the pump or, in this case, the outlet. Cars are usually charged at night when electricity is cheapest. The utility cost is equivalent to a 60-cent gallon of gas, aficionados estimate. A final dividend comes in lower maintenance costs. With few moving parts, electric cars rarely break down. "I still stop at gas stations," says Gadget, "but only to get candy."
By the end of the day, Gadget is far behind schedule. Worse, tomorrow he will not have any of his crew to help him.
Sunday, 11:30 a.m.: Gadget has finally solved the pin problem. Here's what remains to be done: install the batteries and his "box" – the brains of the assemblage – and wire everything together.