Home-built scooter, with photos

[pea]

Hi all,

This won't suit everybody, but some might be interested in my home-built electric scooter project.
Some images below, but many more on my build site www.projectitis.com (http://www.projectitis.com/?cat=20).

It is based on an ebike conversion kit I purchased wholesale from China, mated to one of those adult sized kick/push scooters (like the ones you see kids kicking round on, but with bigger wheels). Its got a 1000W motor (just a tad over the legal limit, but shhh) with a 48V 20AH battery. As yet to test drive it (maybe next weekend?) but range will be about 2hrs. Top speed will not be great because the motor controller limits speed to 480rpm or so, so the size of the wheel (small, in this case) determines top speed. This ebike kit fitted to a mountain bike is capable of well over 70kmh as a comparison.

Oh yes, I've laminated and bent the fairing from two types of thin ply, and upholstered the seat in a retro two-tone racing stripe leather :)

Some background on me: I used to ride a motorcycle before my Wife - and, to be honest, my lifestyle - meant it was replaced by a car. I've still got aspirations to own another one day, perhaps when my kid(s) are older, but to be honest there is probably more luck of one appearing in bits as part of a bike-engined sports car in the future :) I've posted about building a custom scooter on these forums before (a long while ago) and have finally got around to doing something about it.

Cheers. Hope somebody finds it interesting :)

http://www.projectitis.com/wp-content/uploads/2012/01/first-lamination-all-clamped-up.jpg

http://www.projectitis.com/wp-content/uploads/2012/02/20120204-IMG_1353.jpg

http://www.projectitis.com/wp-content/uploads/2012/02/20120205-IMG_1370.jpg

http://www.projectitis.com/wp-content/uploads/2012/02/20120206-IMG_1393.jpg

That link again: www.projectitis.com (http://www.projectitis.com/?cat=20)

[bogan]

That's quite a cool way of doing the bodywork!

Be interested to see what you get speed and range wise on your test drive. I've got an electrified KR-1 (also in palmy so you might have seen me around) that does about 60kph with a bit over 3kW, and gets around 20km out of 1.3kwh of AGM batteries.

[pea]

Hey Bogan, where do you usually ride/commute? I don't think I've seen you around yet!

[bogan]

Awapuni to massey, or awapuni to city center. It's not the most noticeable of vehicles, looks just like a KR-1, but the 1 on the fairing is changed to an E and there are no mufflers, and is pretty quiet too!

[Paul in NZ]

Good onya mate - Kiwi innovation

[pea]

Thanks Paul :)
Bogun - I'll keep an eye out. I work out near Massey.

[Oakie]

I'm speechless. (Well, tapping keys on keyboard-less actually).

Outstanding work! More power to your clamps good sir. First bike that you could tell the age of by counting the rings. :laugh:

[PuppetMaster]

Kiwi ingenuity indeed. The front brakes are a little interesting.

[tigertim20]

it isnt my cup of tea at all in terms of the shape you have chosen to take, but the idea is appealing and interesting.
I could see this in all types of shapes and implemented all kinds of ways.

Out if interest, what are your costs for the necessary parts?

[pea]

Thanks everyone. Hopefully it doesn't get more rings as it ages!

The brakes are a weak point. I don't think those bicycle callipers are going to have much stopping power with the extra weight and speed. The bike shop doesn't have any better ones that fit the same mounts, and the frame isn't designed to take a disc.

Costs for the battery are horrendous, but everything else wasn't too bad.
Bendy Ply (the inner two laminations): $50
Aircraft ply (the outer layers): $100
MDF for former: $40
Glue, rollers etc: $50
Hub motor kit: $200 (incl. shipping)
Donor scooter: $90
The kicker is the battery at around $700 (incl. shipping). There are cheaper options but I went for higher capacity (20AH).

Luckily I have a fairly well equipped workshop/garage with all the tools I needed. Also a lot of friends to call on for clamps!

[Paul in NZ]

It would be cool to make the whole thing in wood..... ie use it as the actual chassis.

Several bicycles use small disk brakes these days - could you graft one of those on?

[pea]

Yeah, the whole chassis from wood would have been cool, but it would have taken a lot more effort. For my first build this is enough :) Check out this for a wooden frame recumbent (http://translate.google.co.nz/translate?hl=en&sl=fr&u=http://blog.borisbeaulant.com/&ei=4KcxT-6gLYepiAfvlcH9BA&sa=X&oi=translate&ct=result&resnum=3&ved=0CDEQ7gEwAg&prev=/search%3Fq%3Dboris%2Bzelo%26hl%3Den%26safe%3Doff%2 6biw%3D1680%26bih%3D935%26prmd%3Dimvnso)- very cool.

Grafting on a disk brake would include welding mounts to the frame. I don't have a welder or any experience welding :(

[Oakie]

Yeah, the whole chassis from wood would have been cool, but it would have taken a lot more effort. :(

Be a bugger having to treat your bike for woodworm or borer attacks. Or woodpeckers!

[Ollie.T]

Be a bugger having to treat your bike for woodworm or borer attacks. Or woodpeckers!

Couldn't insure it for fire either :p

On the plus side, if you dump it in a river it may float!

[Brian d marge]

That battery .....

24kg , and a price to match
great Idea let us know how it goes !

Stephen

[pea]

Hehe! With the amount of glue holding the scooter together - it would probably explode if it caught fire :)
My estimate is around 15kg all up for motor + battery. I should do a proper weigh.

[pea]

I test drove this to work last week. Nothing exploded or caught fire. I lost a couple of nuts (the ones on bolts) on a bumpy section, but they were temporary anyway. Final construction is with nyloc nuts.

32 km/h top speed. Not great, but loads of torque - can do that speed going up hill too, so it is limited by the motor and speed controller. I've enquired about an uprated driver, but with this setup going to a larger wheel size (from 16") seems to be the only way to increase top speed.

Currently have it in pieces again for the final sanding and finishing work. After staining it a little darker it will be clear coated (same as a car) but still retain a timber look.

[The Pastor]

got any more pics?

[pea]

Just the ones on Projectitis (http://www.projectitis.com/?cat=20)

[avgas]

I like it. Keep up the good work.

[pea]

Currently just fixing a few glue spots that need attention. Next steps:

Wire up a master ON/OFF switch (doesn't have one yet!)
Get better brakes or improve the ones its got
Lots of sanding
Staining the timber a bit darker, plus racing stripe
Get it clear coated at the car painters
Put it back together

Also thinking about lights and indicators just in case I decide to register it as a scooter. Probably should :)

[arkeo]

It's amazing and more noteworthy for me given that I am barely able to change the lube oil :eek5: !

[pea]

Thanks arkeo :)
Like all things you start small and work up. I wouldn't recommend this as your first construction project!

[baffa]

Love the design. Can you not use the speed controller to brake the rear wheel, like rc cars? Might help if poss.

[pea]

Hey, great idea baffa! I don't have any options with the controller as it is a closed box supplied by the manufacturer, but I will ask them about it. There is no reverse (doesn't make sense on a bike!) but surely something like that, right?

[Coolz]

Lotsa work gone into that. Well done!