Home-built scooter, with photos

**pea** · 6th February 2012, 20:18

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.

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

That link again: www.projectitis.com

**bogan** · 6th February 2012, 20:36

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** · 7th February 2012, 08:57

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

**bogan** · 7th February 2012, 09:04

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** · 7th February 2012, 10:07

Good onya mate - Kiwi innovation

**pea** · 7th February 2012, 11:00

Thanks Paul

Bogun - I'll keep an eye out. I work out near Massey.

**Oakie** · 7th February 2012, 18:13

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.

**PuppetMaster** · 7th February 2012, 18:30

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

**tigertim20** · 7th February 2012, 18:41

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** · 8th February 2012, 09:09

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** · 8th February 2012, 10:02

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** · 8th February 2012, 10:39

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 - very cool.

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