Cool DIY EV Won't Break the Bank

Electric vehicles may be the next evolution of the automobile, but they sure are expensive. You’re looking at at least seven grand for neighborhood electric vehicles, and even an electric bike costs three grand. The guys at Blue Sky Designs don’t think it should be that way, so they’ve come up with a DIY EV […]

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Electric vehicles may be the next evolution of the automobile, but they sure are expensive. You're looking at at least seven grand for neighborhood electric vehicles, and even an electric bike costs three grand. The guys at Blue Sky Designs don't think it should be that way, so they've come up with a DIY EV that combines the affordability of a scooter with the futuristic look of Boba Fett's space ship.

BugE falls somewhere between an electric recumbent bike and electric car, tipping the scales at 350 pounds, getting about 30 miles per charge and topping out at 50 mph. We're betting BugE's top speed feels faster than that, given the open cockpit, low-slung stance and instantaneous torque electric motors provide. Company founder Mark Murphy realizes BugE isn't for everyone, but thinks there's definitely a market for simple, low-cost transportation that "falls handily between the bicycle and the Buick."

"It is a niche vehicle that's a huge improvement over the scooter, kind of like the Model T of the 21st Century," he says.

The BugE kit Murphy sells from his shop in Oregon includes 75 parts. Ordering can be a little confusing, requiring you to get components from at least two suppliers, but Murphy says he does it that way to minimize costs and maximize options. For $3,500 you get a steel frame with full suspension, a white fiberglass body with acrylic canopy and everything you need to build a rolling chassis. Another $325 gets you a lighting system if you plan on driving after dark.

None of that gets you moving, though. For that you've gotta spend $1,500 for a "power kit" from EV Parts that includes a 3.8-horsepower electric motor, a 48-volt charging system and everything else you need short of the batteries. You're on your own for those. The specs call for lead-acid batteries like those under the hood of the car you've got now, but at least one guy has modded his BugE to run lithium-ion batteries and a 38-horsepower motor. He claims it'll hit 88 mph and do zero to 60 in less than 7 seconds.

All told you're looking at about $5,500, which isn't bad when you consider the Ultra Motor A2B electric bike costs $2,700 and something like the Global Electric Motorcars neighborhood EVs start at $7,300.

BugE is classified as a motorcycle, and Murphy says it's got a range of 30 miles at 30 mph. Go any faster and the range will drop off. The batteries recharge in about eight hours. The canopy flips up to make it easy to catch a breeze, and supposedly there's enough storage room to carry two bags of groceries.

Murphy says he's sold 50 kits in the two years he's been in business, and he claims putting one together is a lot like building a big model car. He thinks assembling one would be a great father-son (or mother-daughter, or... well, you get the point) project, sorta like the Mikey Bike. Of course, not everyone wants to spend a couple of weekends in the garage, which is why outfits like Harvey Coachworks will sell you a turn-key BugE for about nine grand. Murphy hopes to begin selling assembled BugEs at some point, but isn't sure when.

"At this point in our development, we still like to think of ourselves as being way down there in the grass, as mammals among dinosaurs," he says.

Photos: Blue Sky Designs.

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