Why I’d Choose a Used Forklift Motor for EV Conversion If I Started Over in Stage Lighting!

If I Had It All To Do Over Again

Starting off in theatrical stage lighting, lugging around heavy pieces of equipment, fasting the more pared-down lifestyle of today’s tight energy budgets, yet still hoping for clean mobility–I’d still start with a used forklift motor for EV applications. And that may shock you, because at heart I am a stagehand.

Electric vehicles at that time were expensive and something for the wealthy only, or what you’d find at a science fair. I was waist-deep in the logistics of stage equipment all around me and with it fuel (halogen light, diesel generators) crumbled under their combined heat. Our tour truck broke down one weekend in the middle of a festival. It was during this trying time that I pondered one good alternator, plenty fumes and, “What if we electrified our lighting transport system at least?”

That’s basically where it all began for me in motors. Not Teslas or these expensive AC brushless dream machines. Instead, forklift motors. Because we’ve dug used forklift motors for EV conversions out of the rich veins dating any year.

Why Forklift Motors? (And Why You’ve Probably Overlooked Them)

Let’s face it: used forklift motor for EV doesn’t sound very sexy. It’s coarse, industrial and more like something you’d see in a warehouse than it being inside a sleek, silent car. On the other hand it turns out this is precisely why they work so well altogether!

High torque at low RPMs: perfect for carrying stage vans (and carts) with lighting rigs aboard.

Proven durability: built to survive 12 hours on the job, day after day. Week in and week out.

Cost-effective: used ones usually go for $300–$800, vs new EV motors $3,000+.

Also easy to find and recycle – especially if you’re already in the business of shipping gear out to warehouse logistics and staging. This makes them the hidden weapon of DIY engineers.

However, here’s a little busting before we venture further.

Debunking the Myths Around Used Forklift Motors for EVs

Let’s get the top three objections (they were once mine!) out of our way.

? Myth number one: “They’re Too Heavy.”

Of course! Old forklift motors have considerable weight. But a stage van isn’t aimed at winning any drag races-it wants torque and staying power. Weight may be offset somewhat by using lithium ion batteries, and gains in efficiency from regenerative braking will often compensate for this.

? Myth number two: “Old Motors Are Not Efficient Enough.”

Not true! Though they don’t offer the efficiency of some proprietary EV systems, when properly matched DC series forklift motors get a 70–85% energy efficiency, and that’s more than enough for most stage uses.

? Myth 3: “It’s Not Safe.”

Forklift motors are made to industrial safety regulations, that’s just common usefulness. Combined with a smart BMS (Battery Management System), they meet or exceed safety standards for light commercial EVs.

What I’d Do Differently: Lessons from the Trenches

If I could rewind to that festival breakdown, here’s precisely what I’d do.

Start With Component Matching, Not Branding

Before I used to chase well-known brand names. Now? I start with application compatibility. Calibrated correctly, a used forklift motor (paired with a Curtis or Kelly controller) can outperform higher-priced systems.

Real-world Torque Would Be the First Priority Over Top Speed

Lighting trusses, DMX systems, LED walls and so forth are what one finds himself needing to transport. Torque is first. Speed is second. Forklift motors provide that kind of low-end grunt which stage gear haulers dream happy dreams about.

Get Monitoring Tools

In my early builds, I did it differently. I would skip smart monitors now. Not good. Even with a used forklift motor, voltage drops and thermal thresholds are everybody’s friend-and can warn you of troubles to come. Things like the Zeva EVMS or OpenInverter kits go really well with used setups.

How Do Forklift Motors Stack Up Against OEM EV Motors?

Forklift Motor	OEM EV Motor (Nissan Leaf, etc.)
Type of used electric motor designed for forklifts but works in small range electrical jobs	New electric motor designed specifically for cars
$300-$800 (used)	$3000+ (new)
550Nm peak output	200Nm (about 350+ Nm for small cars)

Electric motors can come in many forms. Thus Rosenbluth sees an ease and money-saving that the manufacturers don’t fit into their techniques. He refuses any relocation at all ever, asking the question “Why?” We can do it instead because we always think a few steps ahead. Because of this Japanese approach to electrical systems, two fingertips of oil are enough for these bearings. Lose any more and you’ve got an electrical fire on your hands!

Let me ask you something in a new way. I want to know, do gasoline engines (or cars) have a flywheel location/s at the rear, or within the transmission after all? Roof coverage effect about 2%. At the same time this is a small electric energy component (if combined with an electric motor for cars) makes shopping trips far more enjoyable than ever back home! That’s saying something to the most sensitive of all creatures–mankind.

All in all, here is our answer: unless you’re talking about a true sports car, when it comes time to convert Ford van (or Chevrolet) over from diesel civility on your wallet and values eat away at both, an attempt using used forklift motors as sparkplugs for EV conversions

Real Case: Touring Band Converts Their Lighting Van with a Forklift Motor

Just like everywhere else in this article, musicians have sprung up in other parts of Europe – in this case East Berlin among them. The Touring Bands of those days lived together in squats along the canal with the immigrants and out-of-workers who came after taking a break from factory work are now here making 3&4 (usable) air in your 32MB onboard RAM card machine inside Aixent channelserver!!

After four years of hard work and these guys are getting their photo printed in one of the worlds most influential magazines. This performance business has been kept high through this way, too. In the end Y’all may wonder if this up-and-coming band will still be where they started. For instance, she keeps notebooks full of such expurgations.

91 miles, 95 km/l	$5200 Real conversion expenses
If this towed 65 kg of lighting and audio kit	Pictured on left Its owner lives beside the Canal De L’Ecluse.

It has toured three countries.

Come watch this move, which has in its form toured 3 country. This is more than a hobby – this is now a practical solution, transport business crossings officially community that empowers the use of professional lighting equipment forces. And it all began with is generally thought of as ‘scrap parts’.

What Stage Equipment Professionals Should Know About Purchasing a Used Electric Forklift Motor

If you happen to be in the lights & lighting industry, and especially if your product line is stage equipment, you are no stranger to transport problems. That’s where used forklift motors really shine: literally and figuratively.

High Voltage Matching

Most used forklift motors are designed to be used at 36V, 48V or 72V. Do match a battery system and controller or con-vertion of a stable nature. Don’t just suppose, “more voltage = more power.” 48V systems are ideal for the vast majority of stage applications and strike a good balance in terms of both power and safety.

Choose a Quality Controller

Pairing a good motor with a bad controller is like having a concert where the speakers are blown out. Pick a programmable controller (like Kelly KLS, or Curtis 1238) to allow custom throttle mapping, regen brake set-up, and precise voltage cut-off. This improves safety and also in-creases the life-span of the motor.

Battery Management and Range Estimates

Stage routes can come in all lengths – some only need a few kilometers around the place, others take special days where they’re moving along a city every night. Employ modular lithium packs with BMS integration. Apps such as Batrium or EMUS) give you run-time statistics on the side, allowing you to apportion energy in the correct proportions according to gig schedule.

How to Source Your Ideal Used Forklift Motor (Without Being Stung)

This step really counts. Do not just buy the first motor you see on eBay.

Checklist Before Buying:

All Manufacturer Labels Intact: Make sure the specs are there to see. Look for brands like GE, Curtis, or Hyster.

No Burn Marks or Baked Terminals: A cooked motor will be more trouble than it is worth.

Shaft Play Check: Turn the shaft by hand – there should be only a slight amount of play in it.

Resistance Test: Use a multimeter. The resistance values of all windings should be exactly the same. If the numbers are not equal, as is the case with damaged coils, problems will soon follow.

Clean Armature & Brushes: refrain from dealt with engines caked in hydraulic oil or carbon powder.Protechnique? Find a local forklift repair shop, as they often junk motors in perfect working order during fleet upgrades.

SEO-Backed Bonus: Related Keywords You’ll Want to Know

For search relevance, here are some natural variants of used forklift motor for EV to include in your content strategy or product listings:

EV forklift motor conversion

forklift motor for electric car

repurposed forklift motor for e-van

stage van EV build

industrial motor for EV retrofit

These long-tail keywords squarely aim at search intent without sounding like a machine, and they embrace Google’s semantic indexing while preserving your article’s natural voice.

Final Thoughts From the Road (And the Stage)

If I’d known years ago what I know now—that used forklift motors for EV builds would overhaul how we move stage equipment–I’d have avoided wasting thousands of dollars and scores of hours plus no small amount of environmental worry.

You don’t need to be an electrical engineering guru or a committed tinkerer. You just need to understand the system, source responsibly and consider your professional lighting application. Whether you’re powering a DMX trailer, a modular light rig carrier or an emissionless artist shuttle, there’s an elegant, rough and ready wisdom in reimagining what industrial components can do for your creative career.

For when the lights go down and the curtain opens, it’s not just the show that needs to go smoothly—your gear does too. And putting it all on the muscle of forgotten industrial? That’s not just wise. That’s looking ahead.