Client goal
The problem to solve
Turn an unfinished classic Mini project into something far more exciting than a basic EV conversion, while still making it controllable and usable in real traffic.
Project case study
Tesla Small Drive Unit Classic Mini EV Conversion
Classic car EV conversion / full restoration support
A 1970 Mini EV build using a Tesla Small Drive Unit, 35 kWh battery pack and 7 kW AC charging. The project required major packaging work, drivetrain upgrades, custom shafts, braking improvements, limited-slip differential installation and careful torque mapping to make the car usable on the road.
Discuss a related project
Vehicle / platform1970 classic Mini with front-wheel-drive Tesla Small Drive Unit
Project typeClassic car EV conversion / full restoration support
The brief
What VASS was asked to do
Complete the EV side of the project, replace the original Nissan Leaf-based concept with a more powerful Tesla Small Drive Unit package, integrate the battery and charging systems, commission the vehicle and refine the drivetrain so it could be driven safely.
Scope of work
Defined engineering work
- Removed the previous EV concept and moved to a Tesla Small Drive Unit package
- Serviced and prepared the Tesla drive unit
- Integrated a 35 kWh battery pack packaged around the rear bench area
- Added 7 kW AC charging
- Packaged the EV hardware into the very limited Mini body space
- Commissioned the motor, charging and HV systems
- Arranged custom driveshafts for the Tesla drive unit
- Added wider wheels and a big brake kit
- Added bump-steer and torque-steer improvement parts
- Installed a limited-slip differential in the Tesla drive unit
- Developed smoother torque ramping and selectable drive behaviour
Key systems
Systems involved
- Tesla Small Drive Unit
- 35 kWh battery pack
- 7 kW AC charger
- Custom front driveshafts
- Limited-slip differential
- Big brake kit
- Wide wheel and tyre package
- Torque ramping software
- Eco and sport drive modes
Engineering challenge
What needed careful resolution
- Packaging a powerful EV drivetrain into a very small classic Mini shell
- Making the car controllable despite the extreme torque-to-weight ratio
- Managing wheelspin and torque steer from a front-wheel-drive Tesla motor layout
- Upgrading brakes, tyres and drivetrain hardware to match the EV powertrain
- Balancing excitement with everyday road usability
Practical outcome
The result
The Mini became a very fast and characterful EV restomod. Early testing showed that even a limited power output could overwhelm the original wheels and chassis setup, so the car was progressively upgraded with better brakes, wider tyres, drivetrain improvements and smoother torque delivery. The final setup offered a usable eco mode for normal driving and a stronger sport mode for more aggressive performance.
For similar clients
What this means for another project
This project is a useful example for clients considering high-power EV conversions in small classics. Power is only part of the build. Tyres, brakes, shafts, differential behaviour, suspension geometry and torque mapping all need to be developed together if the car is going to be enjoyable rather than simply difficult to control.
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Share the vehicle, its current condition, the work already completed and the outcome you need. VASS can define a proportionate next step without publishing generic prices.