The Electrified Hauler: How One Engineer Transformed a BMW i3 into a Custom Utility Truck

The global automotive market has long struggled with a paradox: while pickup trucks remain the quintessential vehicle for hauling messy, heavy, or industrial loads, the market for compact, nimble, and fully electric pickups remains virtually nonexistent. While manufacturers like Rivian and Ford chase the full-size electric truck segment, the niche for a small, urban-friendly electric utility vehicle has been left largely untouched. Enter Michael Pick, a dedicated tinkerer and engineer who recently decided to bypass the manufacturer’s roadmap entirely by transforming a pre-owned BMW i3 into a bespoke electric utility truck.

This ambitious conversion project, documented extensively through his personal engineering channels, serves as both a masterclass in custom automotive fabrication and a provocative commentary on the modularity of modern electric vehicles. By stripping away the rear cabin of an i3—a vehicle known for its unique carbon-fiber-reinforced plastic (CFRP) construction—Pick has created a lightweight, zero-emission hauler that challenges the status quo of automotive design.

The Genesis of the "i3-Truck"

The BMW i3, released in 2013, was a forward-thinking experiment in sustainable mobility. Built on a unique chassis that prioritized weight reduction through the extensive use of carbon fiber, the i3 was designed for city commuting rather than rugged utility. However, its rear-wheel-drive architecture and potent electric motor provided an ideal, if unconventional, foundation for a conversion.

For Pick, the project was born out of a practical necessity. With gas prices fluctuating and the utility of a traditional combustion-engine truck becoming increasingly expensive to maintain, he sought a more efficient alternative. The i3 offered the perfect platform: it was compact, agile, and readily available on the secondary market. The transformation process was not merely a cosmetic modification; it required a complete reimagining of the vehicle’s structural integrity and electrical management systems.

Chronology: From Hatchback to Hauler

The conversion process was a multi-stage operation that required careful planning, as the BMW i3’s structural integrity is largely dependent on its "Life Module"—the carbon-fiber passenger cell.

Phase 1: The Teardown

The project began with a comprehensive inspection and a baseline service. After installing a fresh 12V auxiliary battery to ensure the vehicle’s control modules remained operational, Pick meticulously disassembled the interior. This was a critical step, as the i3’s cabin is packed with sensitive wiring harnesses, sensors, and structural bracing that had to be preserved or safely relocated. Once the interior was stripped, the removal of the rear hatch and the surrounding C-pillars commenced.

Phase 2: Structural Modification

The most daunting aspect of the project was cutting into the vehicle. Using specialized tools to navigate the carbon-fiber construction, Pick mapped out precise cut lines. Removing the rear half of the cabin required extreme caution to ensure the vehicle’s chassis remained rigid. Once the rear was opened, the interior void was transformed into a flatbed storage area.

Phase 3: The Custom Bed Fabrication

Building a bed for an electric vehicle requires a delicate balance of weight and durability. Pick opted for high-grade plywood, treated with penetrating epoxy to ensure complete water resistance. To handle the wear and tear of a working truck, the surface was finished with a robust bedliner coating. A major engineering hurdle was sealing the interface between the new bed and the original cabin, as the primary high-voltage electronics and battery management systems are housed in a compartment directly beneath the truck bed. Ensuring a weatherproof seal was not just for aesthetics; it was a safety requirement to protect the core drivetrain components.

Phase 4: Final Integration

The final stage involved the relocation of the vehicle’s taillights. Because the original BMW taillight housing was too large to fit the new, narrower tailgate configuration, Pick designed a custom lighting solution, rewiring the signals to comply with road safety standards. The result is a seamless, functional utility vehicle that looks like it could have rolled off a custom assembly line.

Supporting Data: The EV Conversion Landscape

The i3-Truck is not the first attempt to force a non-truck chassis into the utility segment, but it is one of the most successful examples of a subcompact conversion.

To understand the scale of this achievement, one must look at the constraints of the BMW i3. The vehicle features a curb weight of approximately 2,800–3,000 lbs. By removing the rear hatch and interior trim, Pick likely reduced the vehicle’s overall weight, potentially improving its efficiency—though the aerodynamic drag of an open bed may offset these gains.

In the broader context of the DIY electric vehicle community, this project follows in the footsteps of "Truckla," the viral project by YouTuber Simone Giertz. In 2019, Giertz famously transformed a Tesla Model 3 into a pickup truck, sparking a global conversation about the lack of small, accessible electric trucks. While Truckla used a mass-market sedan, Pick’s use of the i3 highlights the versatility of different EV platforms. Where the Model 3 offered a traditional unibody chassis, the i3 offers a unique, modular platform that serves as a case study in how manufacturers could theoretically produce "stripped-down" utility versions of their existing electric lineups.

Official Responses and Industry Context

While BMW has not officially commented on individual customer modifications like the i3-Truck, the automotive industry has taken note of the growing trend of "micro-utility" vehicles. Large manufacturers have largely focused on the "lifestyle" truck market—vehicles that are massive, heavy, and expensive. However, engineering forums and hobbyist communities have lauded Pick’s work as a necessary "proof of concept."

The project highlights a significant gap in the market: the "kei truck" equivalent of the electric age. In Japan, small utility trucks are the backbone of commerce, yet they are largely absent from North American and European roads. The DIY community, through projects like this, is essentially performing the market research that major automakers seem to be ignoring.

Implications for the Future of Transportation

The i3-Truck is more than just a viral video project; it carries significant implications for the future of vehicle lifecycle management.

The Right to Modify

As vehicles become increasingly software-defined, the ability for owners to modify their cars is under threat. Projects like this emphasize the importance of the "Right to Repair" and the "Right to Modify." If an owner can safely re-engineer a vehicle to better suit their personal needs, it extends the lifecycle of that vehicle, keeping it on the road for years after it might otherwise have been scrapped.

Sustainability and Circular Economy

By repurposing a used BMW i3, Pick has practiced the ultimate form of recycling. Instead of buying a new electric truck—which requires the heavy environmental cost of mining new lithium, cobalt, and nickel—he has breathed new life into an existing chassis. If automakers were to adopt a more modular design philosophy, allowing for factory-authorized or consumer-led "re-purposing" of chassis, the environmental footprint of the automotive industry could be significantly reduced.

Urban Utility

The i3-Truck demonstrates that for most small-scale hauling, we do not need 6,000-pound trucks. A small, maneuverable, electric utility vehicle is more than capable of handling the tasks of the average homeowner, landscaper, or small business owner. By shrinking the form factor, we reduce road congestion, lower the demand on charging infrastructure, and decrease the overall energy required to move cargo from point A to point B.

Conclusion

Michael Pick’s BMW i3 conversion is a testament to human ingenuity and the evolving relationship between consumers and their technology. While it may not replace a heavy-duty diesel pickup for towing a construction trailer, it serves its intended purpose perfectly: it is a practical, efficient, and deeply personal solution to a specific set of needs.

As we look toward an all-electric future, the industry would do well to observe the success of such projects. The demand for utility is not limited to the massive, luxury-focused trucks currently dominating the market. There is a quiet, growing hunger for smaller, more efficient, and highly modular electric utility vehicles. Whether or not manufacturers choose to fill this void, innovators like Pick have proven that the future of the pickup truck might not be found in a factory showroom, but in the garages of those willing to cut, weld, and innovate their way to a cleaner, more useful mode of transport.