What are the obstacles to making GM EV1 replicas, albeit with modern batteries? The design still has merit and would undoubtedly be long range with the lead acid batteries swapped out for something new.
You can get businesses making replicas in small numbers, for example, I am sure you could get a Lancia Stratos, however, would GM have a big copyright ban on such a venture?
Traditionally, lack of demand and the fact that GM was fastidious about keeping them off the road means that they would probably threaten a lawsuit. Electric cars in general have only become popular in the last 5-10 years; the lore of the EV1 has grown accordingly.
Copyright law for art and sculpture requires registration of each design; in searching the copyright records it appears that GM doesn't do this. Really the more appropriate forum would be to get a design patent but those last for only 15 years anyway.
Trademarks must be registered (and also apply to specific categories, though a kit car and production car are in the same category). Surprisngly, "EV1" is owned not by GM, but by Kia (the graphic is different). What this means is you can make the (GM) EV1 logo no problem, and also sell a kit car as something like "inspired by the GM EV1" but if you sell it as an "EV1" then Kia might come knocking.
In short, I don't see much getting in the way of making an EV1 kit car as long as you don't advertise it as a literal GM or EV1 car. Though as stated, you can include or sell separately an EV1 badge that buyers can slap on their own property without issue.
I don't think that copyright would apply because the EV1 design largely serves a functional purpose, and design patent infringement would face an uphill battle for the same reasons. For copyright of a "useful article" the functional aspects of the design cannot be protected, only the artistic ("separability"). For design patents, elements of the design that are dictated by function cannot be protected (N.B., there is some nuance there for alternative designs). The strongest exposure for EV1 replicas is probably trade dress, and the iconic design ("secondary meaning") of the EV1 should strengthen those claims.
Also, trademarks do not need to be registered to be enforced, although it is wise to register them.
They probably would. If the Saturn is older than 25 years, it can be registered as a classic car. The fact that it's highly modified with new parts doesn't really matter. It's what people in the hot rod scene have been doing forever.
For newer cars, you could probably register it as a self-built (kit car).
The states register vehicles, not insurance companies.
And while a big box insurance company might not insure a heavily modified vehicle, there are niche insurance companies who will. Or you could even self insure in a state that allows it.
I imagine it's not hard to get liability/collision insurance on a modified vehicle, and that's all you really need; most insurance will cover damages you cause on "any vehicle" you drive, so it doesn't usually cost much to add an additional vehicle unless it's particularly risky; that this has a real VIN and a real manufacturer should make it pretty easy. If you really think you need comprehensive insurance, you'd need to get specialty insurance anyway, because normal insurance is going to give you a near zero value on a car like that.
Why not? The only issue is if that Saturn was scrapped - once a car is scrapped there is no legal way to get it titled. (but you can still call it home built with parts from the scrapped car - it just needs a new VIN).
You can get businesses making replicas in small numbers, for example, I am sure you could get a Lancia Stratos, however, would GM have a big copyright ban on such a venture?