Otis Singleton
Electric scooters are a fun, convenient, and low-stakes way to get around. While it is relatively affordable to purchase an electric scooter, building one from scratch can be a rewarding experience. This introduction will cover the basics of building an electric scooter, including the key components, design choices, and safety considerations. We will also discuss the process of electrifying an existing scooter and the potential risks of modifying scooter performance. Whether you are starting from scratch or modifying an existing scooter, safety should always be a top priority.
| Characteristics | Values |
|---|---|
| Motor | Brushless hub motor, CIM motors, magmotor |
| Battery | Lithium-ion cells |
| Scooter Frame | Wolf Warrior frame, mountain bike fork, aluminum bars |
| Wheels | 200mm wheels |
| Terrain | All-terrain |
| Speed | 15-25 mph |
| Range | 10km |
| Voltage | Overvolting for higher speed |
| Cost | $400 |
| Time | Six months |
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Choosing the frame
The frame of your scooter should be sturdy and lightweight. You can choose from a wide variety of frame styles, such as a traditional push or kick scooter, a foldable scooter, or even a seated scooter.
If you are using a second-hand kick scooter frame, you may want to build a new deck to triple the width of the original, providing more standing area and space to hang components like batteries underneath. You can use carbon fibre and build a wooden frame with nails spaced every half-inch around its edges, using epoxy to form a smooth, flat sheet.
You can also use 3D printing extensively to design and create the electrical box, LCD screen housing, folding mechanism, and waterproofing pieces.
The main frame of the assembly can be made from 1/4" x 4" lengths of aluminium bar, which can be scavenged from an old school. You can also use aluminium to build a new rear suspension assembly, along with cheap mountain bike shock absorbers.
Make sure your frame has adequate protection for the batteries, and that they are easily removable for charging or replacement.
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Motor options
Hub motors are further classified into geared and gearless variants. Gearless hub motors, also known as direct-drive, utilize electromagnets to directly turn the wheel, typically generating more power and achieving a higher top speed. They are generally heavier, have slower acceleration, but efficiently maintain speed once they get going. On the other hand, geared hub motors employ a gear mechanism to transfer movement to the wheel. These motors tend to have stronger hill-climbing abilities.
Another distinction in motor types is between brushless DC (BLDC) motors and brushed DC motors. BLDC motors are the newer technology, offering better performance, higher efficiency, quieter operation, and improved heat management compared to their brushed counterparts. They also enable regenerative braking, converting excess heat from electronic braking into electricity that can be returned to the battery. BLDC motors are generally more reliable and require less maintenance but may come at a higher cost. For everyday use, BLDC motors are often preferred.
When selecting a motor, it is essential to consider factors such as power rating, voltage compatibility, size, and additional features. The power rating, typically measured in watts, determines the scooter's performance and speed. For casual users, a power rating of 250W to 500W is generally sufficient, while speed enthusiasts or those tackling hilly terrain may require 1000W or more. Higher voltage systems generally produce more power, resulting in faster acceleration, increased torque, and higher top speeds. However, it is important to note that motor wattage is not the sole indicator of performance, as two motors with the same wattage can exhibit different real-world performances.
Additionally, if you plan to use your electric scooter in wet conditions, opting for a water-resistant motor with an appropriate IP rating is crucial. Price and warranty are also important considerations, as higher-quality motors may carry a higher upfront cost but could result in fewer repairs or replacements over time.
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Batteries
Most electric scooters use lithium-ion batteries, which offer high energy density and relatively lightweight construction. Lithium-ion batteries are similar to those used in modern electric cars and provide a good balance between power and weight. They are widely available and have become more affordable in recent years, making them a cost-effective option for your electric scooter build.
When choosing lithium-ion batteries, you will need to consider the voltage, capacity, and discharge rate. The voltage of the battery will determine the power output, with higher voltages resulting in increased speed and acceleration. The capacity, measured in ampere-hours (Ah), will dictate how long the battery can power the scooter before needing to be recharged. The discharge rate, expressed as C-rate, indicates how quickly the battery can deliver its rated current. A higher C-rate means the battery can provide more current, which can be beneficial for high-performance applications.
In addition to lithium-ion batteries, lead-acid batteries are also an option, although they tend to be heavier and have lower energy density. Lead-acid batteries may be suitable for certain applications, but they will make the scooter heavier, potentially impacting its performance and range.
When designing the battery system for your electric scooter, it's important to consider the overall weight and placement of the batteries. Batteries should be securely mounted, preferably underneath the deck or in a compartment that doesn't affect the rider's comfort or handling. Additionally, you will need to include a battery management system (BMS) to protect the batteries from over-discharging and ensure they are charged and discharged safely.
Finally, when selecting batteries, consider the power requirements of your motor and the intended use of the scooter. If you plan to ride on moderate hills or desire higher top speeds, you will need more powerful batteries that can deliver higher currents. It's also essential to choose batteries compatible with your charging system to ensure efficient and safe charging.
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Wheels and suspension
When building a cheap electric scooter, one of the most important considerations is the type of wheels and suspension system you will use. The choice of wheels and suspension will depend on the terrain you plan to ride on and the desired speed and performance of your scooter.
For the wheels, you can choose between smaller or larger wheels. Smaller wheels, such as those found on a Razor scooter, offer less ground clearance and may not be suitable for uneven terrain. Larger wheels, on the other hand, provide better clearance and can handle softer and irregular surfaces more effectively. If you plan to ride on a variety of terrains, consider investing in larger wheels with good tires. You can even upgrade to snowblower tires for riding in snowy conditions.
The suspension system is crucial for a comfortable and stable ride, especially when navigating bumps and uneven surfaces. A basic suspension system typically consists of springs and shock absorbers. You can scavenge parts from old mountain bikes to create a new suspension assembly, as mountain bike shock absorbers can be purchased cheaply online. The spring rate and stiffness are important factors to consider when designing your suspension. The spring rate can be calculated based on the motion ratio of your suspension linkage design, and it will determine the stiffness of the suspension. Additionally, you may need to adjust the preload, which is the amount of pre-compression in the spring, to maintain the desired ground clearance.
Another critical aspect of the suspension is the chain tensioner, especially if you plan to ride on rough terrain. The chain tensioner ensures that the chain remains taut and does not slip off the sprocket when riding over bumps. A simple design involves using an idler in a pivoting arm attached to a spring to maintain tension.
Finally, when selecting a motor for your electric scooter, consider using a hub motor. Hub motors fit entirely into the wheel itself and are popular in modern electric scooters as they facilitate the construction of two-wheel-drive models. Brushless motors are also a popular choice due to their greater efficiency and ability to pack more power into a smaller package.
By carefully considering the type of wheels, suspension system, and motor, you can build a cheap electric scooter that is safe, comfortable, and capable of handling a variety of riding conditions.
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Mods and safety
Upgrading the Motor and Battery:
Upgrading to a more powerful motor can increase speed and acceleration. Look for higher-wattage motors compatible with your scooter model. Keep in mind that a more powerful motor may drain your battery faster, so consider upgrading to a higher-capacity battery as well. Lithium-ion batteries offer a superior power-to-weight ratio but ensure your scooter's controller can handle the increased output.
Tires and Suspension:
Upgrading your tires can significantly improve handling and safety. Consider installing airless rubber solid tires, which are puncture-proof and maintenance-free. Alternatively, switch to off-road tires for rugged terrain or high-performance street tires for a smoother city ride. Larger wheels, typically ranging from 8" to 10", are also a popular upgrade for improved comfort and safety, as they are less likely to get stuck in cracks. Additionally, consider adding or upgrading your suspension system for a smoother ride over bumpy terrain.
Brakes:
Upgrading your brakes is crucial, especially if you've increased your scooter's speed. Hydraulic disc brakes or dual hydraulic disc brakes offer significantly improved stopping power compared to standard mechanical brakes.
Lighting:
Improving visibility is vital for night riding and your safety. Add additional lights and reflectors to extend your field of view and make yourself more visible to other road users. LED lights can also give your scooter a unique aesthetic.
Safety Precautions:
Always wear appropriate safety gear, including gloves, especially when riding in cold weather. Regular maintenance checks are essential to ensure the reliability of your mods. Consult professionals or experienced modders, and always test your mods in a controlled environment. Modifications can void warranties and introduce safety issues, so check local regulations and manufacturer guidelines before making any changes.
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Frequently asked questions
The key components of a cheap electric scooter are the scooter frame and motor. The motor can be belt/gear-driven or direct drive, such as a hub motor. A brushless hub motor has an unmatched power-to-cost ratio.
It is important to consider the terrain you will be using the scooter on. For rough terrain, a wider deck may be more suitable. Additionally, the type of motor and battery will impact the performance and speed of the scooter. Brushless motors and lithium-ion batteries are typically more powerful and lightweight.
Building and riding a modified scooter can be dangerous, so it is important to wear protective gear and only ride in safe areas. It is also crucial to be mindful of the voltage and power of the scooter, as increasing these can enhance the risk of danger and injury.
