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Plug-in Hybrid Conversion

A PHEV Kit can quickly transform a Hybrid car in to a Plug-in Hybrid. The original vehicle gets a boost from an extra battery that gives you the option for all electric city driving.
Plug-in Hybrid Decal
PHEV stands for Plug-in Hybrid Electric Vehicle.
For City driving an Electric car is very economical and for longer drives at high speeds you have the convenience of a petrol engine. A perfect marriage between technologies allowing you to drive to work and enjoy electric city driving at your leisure – it turns heads.
The maze of vehicle technologies is becoming difficult to follow. Many people are aware that a Hybrid car uses an electrical system but it comes as a surprise to discover that hybrids have no plug for re-charging. So we added one.

Hybrids have been around for over a decade.

Boosted Prius Conversion

Add an extra battery to a Hybrid or Electric car and it can run for much longer distances under electric power

A PHEV kit is basically a mobile battery re-charger. It keeps the Hybrid battery topped up.
What’s more, you can plug it in at home with no need for a fancy plug or charging station.

Hybrid Conversion The rechargeable battery charges from a standard household plug, 220-240v AC. Charging time is 4 to 5 hours.

Most city driving is at speeds up to 50km/h. In the city there is a lot of stop and start driving, driving streets with traffic and lights every few kilometres. The extra battery supplies enough power to drive these parts of your journey. At an average speed of 38 km/h a converted Prius can travel up to 40km. A standard Prius can travel around 2km on electric power, after that the engine recharges the Hybrid battery.  Hybrids can also use electric power in a Blended mode.  Blended modes use a mixture of fuel and electric power.  These modes can be used at high speeds.  By using a Booster Kit this high speed Blended Mode can be sustained,  increasing fuel efficiency to 100mpg.  A Standard hybrid reclaims power from the braking system and uses this to help recharge the Hybrid battery. There is enough energy saved to improve driving efficiency. A bit more energy is needed to fully charge the Hybrid battery, braking alone is not enough. In a standard Hybrid the engine is needed to top up the battery. A Booster Kit does the job of topping up the battery.

A Hybrid that has an EV button also has a system that does not need the engine to start for driving, it can be used as an electric car. All driving and electronic functions are powered by the Hybrid battery,  the Booster Kit battery simply keeps it topped up.

Every amp supplied to the traction battery is an amp available for electric driving.
Every kilometre driven electrically is a kilometre saved on fuel.

A 4kWh PHEV kit can drive up to 40km in EV mode, that is a lot of city driving.

Hybrid Booster Kit

Whether you drive a distance of 40 km or you hit the motorways and drive 1000 km, using a plug-in kit, you will reduce your fuel consumption.  Normally city driving burns the most fuel compared to Motorway driving. You can cut your city driving costs down using electric power only. A full charge costs around €1.00.

You don’t have to worry if the rechargeable battery is empty, the car will run as normal, using fuel. With a Plug-in Hybrid you have the freedom to choose where your electricity comes from. Using alternative energy to drive vehicles is not new. Electric, gas, vegetable oil powered cars have been around for a long time. Between traditionally fueled cars and electric cars there is wide variety of choice in technologies. There are pure electric cars, which use no fuel and hybrids which use fuel but have electric propulsion motors in different arrangements. A PHEV, Plug-in Hybrid vehicle offers something in between these technologies. A PHEV can use electric power from environmentally friendly sources. A PHEV is not limited by range. When the battery is empty the petrol engine takes over and drives the car.

Electric assist reduces fuel consumption

Electric assist reduces fuel consumption

 Is it economical?

Potential fuel savings can pay for the kit in four years. The cost of a PHEV conversion is relatively low. This has the potential to get a return on your investment. The battery lifetime can be up to 10 years and only see a degradation in power of 20%. A good battery management system helps to achieve this lifetime. Lithium (Fe) ion batteries do not need to be fully discharged on every cycle. In fact it is better to plug it in after every drive, no matter how short. Li-ion batteries age with deep cycling, aging decreases capacity. The Battery management system does all the worrying for you, very little maintenance is required. The BMS stops overcharging, protects from over discharging, balances the cells to millivolt accuracy, does not allow charging if the battery is too cold or discharging if too hot and records all the data every day for ten years.

A return on the investment can be calculated by comparing fuel costs driving the same car without a PHEV kit. Over time the cost of a PHEV kit should save you more money than you would have spent on fuel. Click here for some calculations that help to illustrate this.
Research shows that PHEV conversion reduces fuel consumption.

Cars That can be Converted:

Most Hybrid car batteries accept charge from Regenerative braking,  this power is mimicked by the kit.

In the table linked below,  the lowest voltage is the official rated voltage.  In operation voltage is usually 20% higher than this. Similar to a 12V car battery which is normally 14V during operation.


Is it easy to install and uninstall? Click here for the 3D PDF Installation Schematic, or take the video tour – click here: There are only four wires to connect and some holes for mounting the kit to the car under the rear floor. To uninstall simply remove the wires and fill the holes, leaving the car in its original state. Original vehicle guarantee is still valid.

The kit is already certified with an E-mark which means no extra certification is needed.

The PHEV kit is not a modification; it is a non permanent addition and as such has no effect upon guarantees. Vehicle Authority certification is not required by the local (MOT/TÜV) centres. You need only be aware of loading the vehicle due to the extra weight of 65kg.

Original Guarantee is still valid
In the USA this was established in a court case under the Moss Magnuson Act. This Act stipulates that a dealer cannot void a guarantee because a vehicle is fitted with aftermarket parts. In 2003 the European Union brought in further legislation affecting the motor trade through the Block Exemption Regulations (BER) which closed loopholes that the guarantee companies were using to get out of paying warranties to their customers. BER states that a guarantee company has to prove beyond all reasonable doubt that the aftermarket addition directly caused an engine failure or impairment to the vehicles performance. The European Commission has declared that any clause to the contrary in a guarantee document would represent ‘an unjustified restriction on the consumer’. To date, there are no reports of the PHEV Kit causing any vehicle parts to fail. Drivers of converted cars have received high levels of cooperation from dealer service departments so far. We agree with Toyota’s comments:

“We’re immensely gratified that some enthusiasts, in a tacit endorsement of the hybrid concept, are, on a vehicle-by-vehicle basis, converting Toyota hybrids to plug-in technology. ”  – Irv Miller, Toyota Motor Sales Group Vice President – Corporate Communications

Conversion Kit Guarantee The batteries have 3 year limitied Guarantee. All other parts of the kit are under guarantee for two years, see Terms and Conditions.

Click here for some calculations that help to illustrate this.