1966 Mustang EV Restomod – Project Proposal

Chosen Drivetrain and Battery Components

Tesla Large Drive Unit (LDU) – Salvage
- Estimated Cost: ~$8,000 (including preventative maintenance)
- Power Output: ~400 kW (536 hp)
- Benefits:
  - Highest performance-to-cost ratio.
  - Integrated motor, inverter, and differential simplifies mechanical layout.
  - Extensive aftermarket support (AEM, EV Controls, OpenInverter).
- Considerations:
  - Perform coolant seal upgrade and spline inspection to mitigate known reliability issues.
  - Select proven aftermarket controller (EV Controls T2-C preferred for ease, ~$3,700; or AEM EV for maximum customizability, ~$2,500).
Tesla Model S/X Battery Modules (Salvage)
- Estimated Cost: ~$10,000 (for ~52 kWh usable capacity)
- Energy Density: ~200 Wh/kg (high performance-density balance)
- Benefits:
  - Widely available and proven reliability in DIY conversions.
  - Good balance of price, energy density, and ease of integration.
  - Strong existing knowledge base and aftermarket solutions.
- Considerations:
  - Essential to install effective thermal management and a robust Battery Management System (BMS).

Cost: ~$1,570
Benefits: Automotive-grade reliability, excellent safety, intuitive installation.

Item	Est. Cost
Roadster Shop SPEC Chassis + Brakes	$16,415
Rust Repair (120 hrs @ $100/hr)	$12,000
DIY Single-stage Acrylic Paint	$1,500
Body-to-Chassis Alignment	$2,000
DIY Chassis Finishing (POR-15)	$300
Miscellaneous Body Supplies	$500
Subtotal:	$32,715

Item	Est. Cost
Tesla Large Drive Unit (Salvage)	$8,000
EV Controls T2-C Controller	$3,700
Custom DIY Motor Cradle & Mounting	$1,000
Half-Shafts & CV Joints	$1,300
HV Harness, Contactors & Cabling	$1,200
LV Wiring & Ancillary Electronics	$1,000
Elcon 6.6 kW Charger	$1,835
Orion BMS 2	$1,570
Battery Module (Tesla, ~52 kWh)	$10,000
Battery Enclosure (DIY Materials)	$1,000
Cooling Hardware	$600
Subtotal:	$31,205