I am using the 9" FB1-4001A from ADC. Since this is my first conversion I decided to take the road of "I don't know anything" and use the experience of the experts of the EV community on the internet. The one I'm impressed with the most is Bob at EV America. He did my calculations to make sure I could pull it off in the 240 and he's the cheapest around for the $$$ parts such as the motor, charger, and controller. I'll be building a 144 volt system using Trojan T-875s due to weight. 145s would be better but they're a bit heavy. I'll be using the Curtis 1231C-8601 controller. Everything is rated for 500 amps.
For the drive, I'm swapping out the AT for a M46 manual and will be using a "clutchless" drive. Shifting will still be possible but with a 2 second or so lag. The clutchless configuration eliminates the clutch pressure plate and flywheel. That's about 60 lbs savings but translates into about 1000 lbs rotational weight! Speaking of weight, finished weight comes in at 3988 lbs which includes 2 adults, 2 kids and 50 lbs of groceries. I have other weigh reducing ideas but need to investigate the structural issues. I'm hoping to get 60 miles range. Driving to work w/o wife and kids should be possible. I'm working on convincing my employer to let me plug in however.
No, the 240 isn't the ideal EV conversion for several reasons but it's built like a tank, the price was right (for a car that has only seen one MI winter), and it will be a nice change from the VW Bug, Ford Probe, and S-10.
If I missed somethng just let me know.