Trystan Casey
Building your own electric skateboard can be a fun and rewarding project that allows you to customize your board to your needs. The process involves selecting and assembling various components, including the motor, battery, and electronic speed controller (ESC). You can choose from different options, such as a high-performance board with speeds up to 40 mph or a cheaper alternative with longer shipping times. When choosing an ESC, it's important to select one specifically designed for electric skateboards to handle high currents and heat. You'll also need to consider the KV-ratio, which affects the torque and speed of your board. Building your own electric skateboard gives you the freedom to decide which components are most important to you, whether it's speed, torque, or battery life. Additionally, you can choose to create your own enclosure to protect the electronics from water and damage, using materials like wood, metal, or 3D printing.
Characteristics and Values of Creating Your Own Electric Boards
| Characteristics | Values |
|---|---|
| Top Speed | 26-47+ mph |
| Range | Depends on rider size, riding style, and terrain |
| Battery | 6s2p or 6s3p lithium-ion battery, 10s battery, lipo battery |
| Motor | 95-amp, 2 motors |
| Deck | Longboard deck, carbon fiber, plyboard |
| Wheels | Large diameter, medium softness |
| Trucks | Extended |
| Cost | $300-350 |
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What You'll Learn
Choosing the right deck
When choosing a deck, it is essential to consider the type of skateboarding you plan to do, your riding style, level of experience, and personal preferences. Skateboard decks come in various shapes, sizes, and materials, each designed for a specific style of skating. For example, if you're into street skating, you may prefer a smaller deck that's easy to manoeuvre and flip. On the other hand, if you're more into cruising and carving, a larger and more stable deck might be a better option. Longboard decks, typically ranging from 33" to 60" in length, offer more stability and a smoother ride, making them a popular choice for electric skateboards.
The wheelbase, or the distance between the inner mounting holes, determines the stability of the board. A wider wheelbase will provide a more stable ride. Additionally, the shape and design of the deck are important factors, especially when considering the placement of the motor mount and other electronic components.
The deck's material is another crucial aspect. Maple is a common choice due to its sturdy and reliable nature, while bamboo is popular for its lightweight and flexible properties. The number of plies, or thin layers of wood, in the deck can also affect its performance and flexibility. Most longboard decks have 9-ply construction, while typical skateboards have 7-ply.
When building your own electric skateboard, it's important to consider the placement of electronic components and batteries. A solid enclosure with good airflow and sturdy construction is necessary to protect these components. The existing walls of the enclosure can provide structure and potential places for mounting, and thick wires must be used to handle the high current of electric skateboards.
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Selecting a motor
When selecting a motor for your electric skateboard, there are several factors to consider. Firstly, decide whether you prefer a belt motor or a hub motor. Belt drives deliver better torque than hub drive motors, even for the same price. They also allow for larger wheels and provide more room for customization. On the other hand, hub motors are widely used due to their relatively inexpensive parts and their clean and simple implementation. They are quiet, stealthy, and popular among skateboarders.
Another important consideration is the power of the motor. The power output of electric skateboard motors can vary significantly. Simple hub motors typically have a power output of 250W or 350W, while more powerful options like the Enertion R-Spec Ghost offer 1680W. Outrunner motors, such as the Wowgo 3X, often provide higher power outputs, ranging around 600W. If you're looking for a DIY solution, you can find motors with power outputs ranging from 1000W to 4000W.
The KV-ratio, or KV value, is another critical factor in choosing a motor. KV stands for revolutions per minute (rpm) per volt applied to the motor. A higher KV value means the motor spins faster but produces lower torque. For electric skateboards, the usable KV-ratio is typically between 100 and 300 KV. If you have a high-voltage battery, consider choosing a motor with a lower KV value to maintain a suitable rpm. For example, a 300 KV motor combined with a 37V battery results in a high rpm of 11,100.
When selecting a motor, it's also important to consider the size of the stator and the motor can. While a larger motor can size usually indicates a more powerful motor, the strength of the motor depends on various factors such as internal construction, magnet type and shape, and the air gap between the stator and can. Therefore, it's advisable to ask the manufacturer for the stator size, as this, along with the motor size, provides a better indication of the motor's power.
Lastly, consider the speed, torque, range, and motor volume requirements for your electric skateboard. These factors play a crucial role in determining the performance of your skateboard and should not be overlooked. Ensure that the maximum current the motor can pull is compatible with the ESC (Electronic Speed Controller) to avoid damaging it.
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Picking a battery
Lithium-ion batteries are the most popular type due to their lightweight, high energy density, and long life. They are also more expensive than lead-acid batteries but are worth the investment for a high-quality board. On the other hand, lead-acid batteries are heavier and have lower energy density. They are also cheaper and take longer to charge, typically up to 12 hours.
Most electric skateboards need their batteries to be at least 30A continuous. The voltage of the battery is another important factor, as it determines how much power it can supply to the motor. Electric skateboard batteries typically have a voltage of 24V to 48V. The higher the voltage, the more power the motor can provide, but this also means higher costs and weight. The capacity of the battery, typically between 5Ah and 10Ah, determines how much energy it can store and is measured in ampere-hours (Ah). The higher the amp-hour rating, the longer the battery life.
The size and weight of the battery are also important considerations. A heavier battery will make the board harder to manoeuvre and less portable. The size of the battery will determine where it can fit on the board, so it is important to measure the available space.
Finally, the charge time of the battery is a critical factor, especially if you plan to use your board for commuting. A lithium-ion battery typically takes 2 to 4 hours to charge, while a lead-acid battery can take much longer.
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Enclosure design
When creating your own electric board, the enclosure design is a crucial aspect that requires careful planning and consideration. Here are some detailed instructions and tips for designing and building an effective and attractive enclosure:
Planning and Layout:
Start by gathering all the electronic components, connectors, buttons, switches, and other elements you plan to include in your electric board. Lay them out on a flat surface and arrange them compactly, making sure they fit together logically. This step is crucial to ensure that all the parts will work together harmoniously within the enclosure. Remember to consider the placement of panel-mounted switches or lights and how to minimise cable lengths by adjusting their position.
Size and Clearance:
The size of your microcontroller will determine the size of your enclosure. Consider how much space you need above and below the PCB to calculate the exterior dimensions accurately. Even if you have a single large component protruding from the board, ensure you make any necessary adjustments to the effective volume of the enclosure while the design is still flexible.
Template Creation:
Spend time creating a detailed template to avoid mistakes and ensure a smooth building process. You can use software like Illustrator to create templates and lay out the actual parts inside the box. Consider the connections and leave enough room for cables, connectors, and screws to fit without any components bumping into each other. Printing out several templates and comparing them can help you choose the most efficient design.
Drilling and Mounting:
Once you have your layout and template finalised, it's time to drill the holes for mounting the circuit boards and other components. Use a marker to indicate the mounting holes and a punch to create an indentation for drilling. Drill pilot holes to find the exact centre, then use the appropriate drill bits and tap sets to create the final holes. If you're using PCB standoffs, you can use the sticker backing or drill the standoffs for a more secure fit.
Assembly and Connections:
After drilling the holes, it's time to assemble the components and make the necessary connections. Test fit all the connectors and glue or screw them into place. For connectors that require gluing, use an expanding glue like Gorilla Glue and clamp them overnight. For screw-in connectors, drill and tap the holes as needed. Ensure that all connections are secure before mounting the electronics.
Customisation and Off-the-Shelf Options:
If you want a unique design, you can customise your enclosure by drilling holes, silkscreen printing, or using a plastic laminate like "Forex". Alternatively, consider off-the-shelf options from companies like OKW Enclosures and Polycase, which offer customisation for small orders. You can also explore 3D printing or using aluminium or steel enclosures for your electric board.
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Electronics assembly
The process of creating your own electric board involves assembling a printed circuit board (PCB) and turning it into a printed circuit board assembly (PCBA). This is achieved by connecting electrical components to the circuit board. Here is a step-by-step guide to the electronics assembly process:
Step 1: Understand the Basics
Before you begin, it's important to know that there are four main types of electronic components: through-hole passive components (resistors, capacitors, inductors, etc.), through-hole active components (diodes, transistors, integrated circuits, etc.), and surface mount passives and actives. Passive components are generally straightforward, but it's important to observe the polarity of electrolytic capacitors.
Step 2: Gather Your Tools and Materials
You will need a set of basic tools for assembly. These include a small wire cutter, small pliers, a soldering iron, a dental probe, a volt/ohm meter, magnifiers, a work light, and an anti-static mat with a wrist strap. It is also recommended to have solder removal tools and a damp sponge for cleaning your soldering iron.
Step 3: Prepare the PCB
Start by applying a paste to the PCB using a screen printer and a thin stencil. This will ensure that the paste only goes where it is needed on the board. The paste is made of microbeads of metal, which will melt in the oven and create solid connections.
Step 4: Place the Components
On a one-layer PCB, insert the components and gently bend the leads to hold them in place while you solder. For multi-layered PCBs, you will likely use surface-mounted components, which can be placed more densely.
Step 5: Soldering
Hold your soldering iron at a 45-degree angle and touch the tip to both the lead of the component and the PCB. Apply solder from the opposite side, heating the surfaces until the solder flows freely. Be careful not to overheat the pad, as it can damage the PCB.
Step 6: Oven and Cooling
After all components have been placed and soldered, put the PCBA in the oven to melt the paste and create solid connections. Once it's cool, your electric board is ready for use!
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Frequently asked questions
An electric board is a regular skateboard with a few extra components. You need a motor, a battery to power the motor, an electronic speed controller, and a remote control for the throttle and braking.
A brushless DC motor is recommended for electric skateboards because of the power it can deliver in a small motor. The KV-ratio is an important specification, as it determines the motor's speed. The usable KV-ratio for electric skateboards is between 100 and 300 KV.
Most people use Lithium Polymer (LiPo) batteries as they provide a lot of power for their size and weight. However, they need to be handled carefully to avoid a fire risk.
A longboard deck is recommended as it offers more stability, a smoother ride, and more space for your components. The deck should be solid with little flex and top-mounted rather than drop-through trucks to provide more room underneath for the electronics enclosure and motor.
You can buy parts and kits online from sites like AlienPowerSystem, Banggood, and Aliexpress. Be careful when buying an ESC as most on the market are designed for RC cars and cannot handle the high currents and heat generated by your motor. Ben Vedder's VESC is a popular option designed specifically for DIY electric skateboards.
