There are quite a few electric Mini conversions around. I found several on a google search and on YouTube. You should try contacting some of the builders and see what they did. Also, I know that EV West did a Moke conversion. They might be a good source for information. www.evwest.com

The Mini suspension, including wheels and tires - and more imprtantly brakes - is designed to serve a specific weight range - from empty to fully loaded. Assuming, very roughly 2 passengers with a total weight of 350 to 400 lbs, your all-up weight will be 1010 to 1080 lbs. or about 150% of the maximum design load. Look for a car that will support the new load and see what size the wheels, tires, suspension components (all of them including shocks) it has. Then look at the Mini's. That's how much you will have to beef up the Mini. To see how it might be done, watch the project Binky series episodes on suspension.

I'm going to convert my Mini Mayfair to electric. Part of the process is that I'm going to install battery packs that will weigh 680lbs. The original manual for the Mayfair said that maximum weight is 700lbs - which means if I sit in the car it will exceed the maximum weight!

What can I do to the suspension to make it comfortable carrying the weight as a daily driver?