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I came across this thread on a Google search for scratch built EV's. I've been mulling ideas over in my head for a while and I like the look of some of the stuff I'm seeing on this thread. My idea centres around a Lotus 7 replica chassis (Caterham, Westfield, Locost). You might want to research these for fabricated front suspension parts. There is no reason that custom fabbed parts should last less time than OE parts, if they are properly made. I agree with the comments on ATV parts though - don't touch them!
I'm nowhere near the same stage as yours, but as said, my idea is based on the small, light and strong '7' style spaceframe chassis, possibly made from aluminium tube. Rather than the traditional bodywork however, I think a smoother, more integrated shell might be better. My design goal is to get me to work and back on each charge, with a bit of extra range for lunchtimes etc, totalling about 50 miles. It will probably be a 2 seater, but mostly used for me only.
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