Legacy EV & HP Tuners: Redefining Electric Conversions with CORE EV

Legacy EV & HP Tuners Team Up on 800V Porsche 911 and Purpose-Built VCU

In a groundbreaking partnership, Legacy EV and HP Tuners have teamed up to electrify a 1984 Porsche 911 Carrera, turning it into an 800-volt powerhouse. This ambitious project not only pushes the boundaries of electric vehicle (EV) conversions but also serves as a real-world testbed for HP Tuners’ newly developed Vehicle Control Unit (VCU) the CORE EV designed to optimize aftermarket EV systems. 

A Powerful Partnership

The collaboration between Legacy EV and HP Tuners is a perfect marriage of expertise in electric systems and cutting-edge tuning technology. HP Tuners, known for its advanced software solutions and tuning tools, selected Legacy EV for its unrivaled knowledge in high-voltage electric conversions.

“Legacy EV helped us choose the best components for high-performance applications,” explained Vinay Hasija, EV Engineer at HP Tuners. In addition to providing components, Legacy EV delivered a tailored education course to HP Tuners, further enhancing their understanding of high-voltage systems. This collaboration reflects Legacy EV’s broader mission to support and connect players across the EV ecosystem, helping manufacturers, integrators, and innovators shape the future of automotive technology.

As Rob Ward, CEO and Founder of Legacy EV, puts it; “We’re playing a critical role in developing integrated systems that simplify the conversion process for everyone. Our goal is to bridge the gaps in the industry, making it easier for companies to bring electric solutions to market.”

Classic Porsche, Modern Power

At the heart of this pioneering project is the iconic 1984 Porsche 911 Carrera. Renowned for its timeless design and devoted fanbase, the Porsche 911 has long been a symbol of classic motoring excellence. Legacy EV, a leader in high-voltage electric vehicle conversions, took on the ambitious challenge of transforming this automotive legend into an 800-volt electric marvel.

In just four months, Legacy EV designed and installed a complete EV system, featuring Cascadia Motion’s iDM-375SiC Integrated Drive Module, boosting the Porsche to 635 horsepower and 435 ft-lbs of instantaneous torque. Powering this high-performance motor is a custom-built 800V, 76.5 kWh battery pack capable of DC-fast charging and specifically engineered to fit the car’s tight frame. The battery system now delivers the kind of performance you’d expect from a Porsche while also meeting the rigorous demands of a development test mule.

This Porsche 911 project is more than just an electric conversion—it’s a glimpse into the future of the automotive aftermarket

The commissioning process for the CORE EV was a collaborative effort between HP Tuners and Legacy EV engineers, ensuring the Porsche’s transition to electric power was seamless. “We worked side by side on initial vehicle programming and VCU pinout wiring,” Rory Baldrey, Head of Research and Development at Legacy EV recalls. “When we finally saw the wheels spinning, it was a real milestone for the project.” This hands-on collaboration was key to successfully bringing the 800V electric Porsche to life.

“I couldn’t be prouder of our R&D team,” shares Ward about the build process. “The work they’re doing is incredibly exciting, and I’m thrilled about where we’re headed as a company and an industry. It’s inspiring to know we’re shaping the future.”

Building the Brain: HP Tuners’ VCU

The real game-changer in this project is HP Tuners’ CORE EV, a central brain designed to manage all the essential components of an electric vehicle. When HP Tuners set out to develop its VCU, the  mission was clear: create a powerful yet easy-to-use system that can seamlessly integrate with aftermarket EV setups.

The VCU was engineered to be intuitive and simple to configure, reducing the chance of user error and making the setup process as smooth as possible. HP Tuners wanted to ensure that even those new to EV conversions could get up and running with minimal technical headaches. “We took a ‘less room for mistakes’ approach,” Hasija explained, ensuring that the VCU is not only powerful but also approachable.

But HP Tuners didn’t stop at simplicity. The VCU is also designed to be robust and future-proof, with both hardware and software developed in-house specifically for electric vehicles. It’s built to withstand the harsh conditions that EVs often face, from extreme temperatures to demanding driving conditions. Looking ahead, HP Tuners designed the VCU with future advancements in mind, including the potential for integration with artificial intelligence (AI) and other cutting-edge technologies. “We wanted to create a product that users can grow with,” Derek Morley, Director of Powertrain Engineering at HP Tuners shared, emphasizing the CORE EV’s versatility and adaptability.

Tackling the Challenges of EV Conversions

Converting a gasoline-powered Porsche 911 into an 800V electric vehicle wasn’t without its challenges. The most significant hurdle for Legacy EV was battery placement, as the car’s design left limited space for the 76.5 kWh battery pack. “One of the toughest parts was designing the battery pack to fit the limited space in the rear,” said Baldrey. The tight packaging required creative engineering solutions to ensure the car maintained its performance while providing new and improved weight distribution.

For HP Tuners, working with high-voltage systems and managing complex communications between various EV components was a new frontier. Integrating a reliable and fast CANbus communication system—used to relay data between the VCU and other vehicle systems—was a significant technical challenge. To address this, HP Tuners developed its  own in-house CAN protocol, ensuring seamless communication and integration across all components.

Safety was another major consideration. As with any high-voltage system, ensuring that the VCU and other components were safe for both professional installers and hobbyist users was critical. Extensive testing, including hardware-in-the-loop simulations and real-world validation, helped HP Tuners ensure CORE EV was as safe as it was powerful. “We spent a lot of time on safety features, ensuring that end-users and installers would always be protected,” said Hasija.

Next Steps: Style Meets Performance

With the mechanical transformation complete, the project now shifts toward enhancing the car’s aesthetics. Forgeline Wheels is developing custom wheels to complement the Porsche’s sleek, electric-powered stance, while Achtung  Kraft is responsible for the interior and exterior upgrades. These modern touches will enhance the car’s performance-focused design while preserving its classic 911 look.

A custom livery, along with a high-performance brake system from Brembo, will further elevate the car’s appearance and performance, ensuring that this electrified Porsche is as stunning to look at as it is to drive. The attention to detail in both performance and design speaks to the level of craftsmanship involved in this project.

Leading the EV Conversion Revolution

This Porsche 911 project is more than just an electric conversion—it’s a glimpse into the future of the automotive aftermarket. By combining the timeless appeal of a classic car with state-of-the-art 800V technology and a revolutionary new controller, Legacy EV and HP Tuners are setting new standards in the EV conversion space.

For HP Tuners, CORE EV represents a significant leap forward in EV technology, offering a versatile, user-friendly system that can adapt to the needs of a growing EV market. For Legacy EV, this project is an opportunity to showcase their commitment to innovation. “Innovation is in our DNA,” said Ward. “This project reflects our dedication to leading the EV revolution in the aftermarket space.”

As the aftermarket shifts towards electric, partnerships like Legacy EV and HP Tuners are leading the charge. Discover more about their respective cutting-edge work at legacyev.com and hptuners.com.