Still not sure what pack voltage yet.
Golf carts and NEVs use 48V systems, but I would like to get some better performance than that.
However, the higher the voltage, the greater the cost. Ideally, I would like to get new batteries donated to me. There is a battery manufacturer near me that I might be able to get some sort of sponsorship from. Also, Johnson Controls is in Milwaukee. They have a battery division that is working on new battery types, specifically for hybrids and electric vehicles. I have heard that if you can get in touch with the right person, they may actually LOAN you fancy batteries, so they can get real-world test results for them.
Another EV guy told me that I should do at least 120V. At that point, you can build your own charger real cheap using some inexpensive 120V AC equipment.
72 Volts seems like a natural, because I have the 36V forklift charger, which could charge the 72V split into 2 36V packs.
Commercially available motor controllers jump in price above 48V and 72V, so I only have one price jump if I bought a controller new.
Where I am, I shouldn't need a vehicle inpection or anything like that. Typically you just pay the title and registration fee, and then have to take the vehicle for emmissions (tailpipe) testing.
My old motorcycle was completely exempt from that. I am not sure what I would need to do for the car. I would imagine that the "hobbyist" plates would almost make a vehicle automatically exempt from emissions. I can't imagine antique cars and hot-rods all passing pollution testing!?!
I would put a new clutch in and then go register and get tested, but it seems like taking everything out to get a new clutch in is half the work of doing the conversion anyhow!