Turning a 1997 Subaru Sambar into an EV with 120 HP and Zero Emissions
BigTime and Legacy EV rip the 39 HP gas engine out of a 1997 Subaru Sambar and replace it with a NetGain Hyper9 making 120 HP and 162 lb ft of torque. The result: a kei truck that is faster, quieter, and cleaner than it ever was from the factory.
TL;DR: The BigTime crew, with Ludwig Ahgren producing, pulled the tired 658cc EN07 engine from a 1997 Subaru Sambar and replaced it with a NetGain Hyper9 electric motor making 120 horsepower and 162 lb ft of torque. That is more than three times the original output. The battery pack is 32.9 kWh, the estimated range sits between 80 and 120 miles, and the entire exterior remains bone stock. This is one of the most complete, well documented kei truck EV conversions to date.
The 25 year import rule has flooded the US market with kei trucks from the late 1990s. Most of them arrive with low mileage engines that still run strong, but the EN07 in a 1997 Sambar is not exactly a powerhouse. It makes 39 horsepower, 39 lb ft of torque, and drinks fuel through a carburetor that does not know what emissions standards are. For Jeremiah Burton and the BigTime channel, the answer was not a turbo kit or an engine swap from a bigger Subaru. It was ripping the combustion engine out entirely and going electric.
Why the Sambar Is a Great EV Candidate
The Subaru Sambar has a rear engine layout with switchable four wheel drive, a 5 speed manual transmission, and a curb weight under 1,800 pounds. That combination makes it one of the better kei trucks for an EV conversion. The rear engine bay provides a natural home for the electric motor, the low curb weight means a modest battery pack can deliver real range, and the existing four wheel drive system gives the converted truck traction in conditions where a rear drive only setup would struggle.
Compare that to a front engine kei truck where the motor sits under the cab. Pulling the gas engine out of a Suzuki Carry or Daihatsu Hijet means working in a space that was never designed for easy access, and packaging a battery under the bed while keeping the motor up front adds complexity. The Sambar's layout puts the heavy components closer to the rear axle, which also happens to be where you want the weight when the bed is empty.
The team at Legacy EV in Tempe, Arizona provided the components and expertise. They specialize in EV conversion training and kits, and they used this build as a real world case study for their EV Build Fundamentals curriculum. The parts came from a decommissioned training bench rather than new stock, which kept costs down and gave second life to components that would otherwise sit on a shelf.
The Hyper9 Motor and Battery Pack
The heart of the conversion is a NetGain Motors Hyper9, a three phase AC synchronous reluctance motor that weighs about 130 pounds and produces 120 horsepower with 162 lb ft of torque at zero RPM. That instant torque figure matters. The original EN07 needed to wind past 4,000 RPM before it made peak power. The Hyper9 delivers maximum twist the instant you press the pedal.
The battery pack uses 14 Kore Power modules arranged in an alternating PN/NP configuration, totaling 32.9 kWh at 175 volts. A custom aluminum battery box designed by Send Cut Send houses everything under the truck bed. A Dilithium Designs BMS handles voltage monitoring, temperature management, and cell balancing. The onboard charger is a TSM2500 pulling 3 kW, and the J1772 charge port sits exactly where the factory fuel filler used to be. That last detail is the kind of thoughtful integration that separates a clean build from a hack job.
The drivetrain uses a 1.9:1 torque box mated to a repurposed front differential mounted in the rear. The team added tubular framing and a custom fabricated crossmember to handle the additional stress. Everything outside the drivetrain, from the suspension and brakes to the body panels and interior, remains completely stock. You would not know this truck is electric until you turn the key and hear nothing.
Range, Practicality, and the Numbers
The estimated range of 80 to 120 miles will not impress anyone used to a Tesla Model 3. But kei trucks are not highway cruisers. They are farm trucks, job site haulers, and around town runabouts. If your daily use involves trips under 50 miles, this Sambar can handle a full day of work and charge overnight on a standard Level 2 outlet. That usage pattern matches how most kei truck owners actually drive. The buying guide covers what to look for in a kei truck before purchase, and range requirements should be part of that calculus if you are considering an EV conversion.
The 771 pound factory cargo capacity takes a hit from the battery weight, but the redistribution is actually an improvement. With the gas engine in the rear and nothing up front, the stock Sambar is tail heavy when the bed is empty. The battery pack under the bed creates a more balanced weight distribution, and the team reported improved handling as a result.
For anyone thinking about insurance on an EV converted kei truck, the conversation with your agent will be interesting. Most specialty vehicle insurers classify conversions as modified vehicles, which can affect coverage and premiums. Call before you build, not after.
What This Means for the Kei Truck Scene
EV conversions are still the exception in the kei truck world, not the rule. Most owners are perfectly happy with the stock 660cc engine making 40 to 50 horsepower. The off road mods guide covers the kind of modifications most people actually do: lift kits, all terrain tires, LED bars. But the BigTime Sambar build, alongside Andy Didorosi's 550 HP twin Tesla Suzuki Carry Sendpai project, proves that the platform can handle serious powertrain changes.
The cost question is real. A NetGain Hyper9 motor kit runs $5,000 to $7,000 depending on configuration. A 32 kWh battery pack adds another $8,000 to $12,000 for cells, BMS, and housing. Factor in the charger, DC to DC converter, wiring, and fabrication labor, and you are looking at $15,000 to $25,000 all in, not counting the donor truck. That is serious money on top of a vehicle that costs $5,000 to $10,000 to import. The economics only make sense if you value the project itself, not just the end result.
Conversion kits specifically designed for kei trucks are starting to appear from companies like CMVTE, which offers packages with motors, controllers, and battery systems sized for the platform. As more kei trucks from the early 2000s become eligible for import under the 25 year rule, the supply of donor vehicles will only grow. Check your state's registration requirements before starting any conversion project, because some states treat EV conversions differently than stock vehicles.
The r/keitruck community has been following this build closely, and the MiniTruckTalk forums have active threads on EV conversion feasibility. If you want a deep dive into the technical side, the EV Builder's Guide breakdown covers every component in the Sambar build with engineering detail that the YouTube video does not have time for. And if you are just kei truck curious and not ready for a full powertrain swap, start with the basics and browse the dealer directory to see what is available near you.
