Beatrice Lang
Building an electric cooler scooter is a fun DIY project that can be taken on to avoid the high cost of purchasing one. The process involves designing a frame that fits the cooler snugly, ensuring stability, and constructing a steering system. The fabrication process can be challenging, but with careful planning and the reuse of certain parts, it is possible to create an efficient and unique electric cooler scooter. Safety is a key concern, with helmets being essential when riding these karts, which can reach speeds over 25 mph.
| Characteristics | Values |
|---|---|
| Cost | The cost of building an electric cooler scooter can vary depending on the materials used and whether one has to purchase them. One source estimates that the cost could be around $150 if one has most of the required materials, and around $500 if everything has to be purchased. |
| Design | It is recommended to create a 3D model of the desired design to visualise the required parts and how they fit together. |
| Frame | The frame should be made from aluminium angle, measuring 40" long and 15" wide to fit the cooler snugly and provide stability. It can be welded together using a mig welder spool gun or bolted together. |
| Steering | The steering system can be fabricated from scratch, excluding the handlebars, which can be sourced from a Razor scooter. |
| Wheels | The rear axle should have driven wheels that can be created by welding keyed sleeves into two of the wheels using a regular mig welder. The front spindle mounts should be bolted to the frame, and spindles can be added to create a rolling frame. |
| Axle | The axle should be mounted using aluminium angle and 3/4" bore flange bearings. Ensure the axle is square to the frame to avoid issues when driving. |
| Cooler | The cooler can be mounted by drilling four holes through it and bolting it to the frame. Use extra-large fender washers inside the cooler to prevent tear-out. |
| Battery | AGM battery packs can be placed under the frame, and later upgraded to Lithium batteries for added range. |
| Performance | The electric cooler scooter can reach speeds over 25 mph and can carry two adult riders with a fully loaded cooler. |
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What You'll Learn
Designing the scooter's frame
When designing the frame, it is essential to consider the intended use of the scooter. For example, if the scooter is for commuting or casual riding, a standard or electric scooter frame would suffice. On the other hand, a freestyle scooter frame is more appropriate if the scooter will be used for stunts and jumps. The intended use will help narrow down the options and specific requirements for the frame design.
The durability and build quality of the frame are crucial, especially if the scooter will be used intensively or on rough terrain. A sturdy frame with a high weight capacity will enhance the scooter's durability. Additionally, the frame should be designed to accommodate the weight of the user and any additional cargo, ensuring it can withstand the stress of acceleration and turning.
When selecting materials for the frame, consider using steel or aluminum for the vertical bars to increase strength and resistance to wear and tear. For the construction of the frame, you can either weld or bolt the pieces together. Welding provides a stronger hold, but bolting is a more accessible option if you don't have welding equipment.
It is also important to consider the placement of the motor and battery within the frame design. The motor mount should be designed to support the weight of the user and the torque of the motor. Additionally, ensure easy access to the battery for charging and maintenance.
Overall, designing the scooter's frame requires careful consideration of the intended use, durability, materials, construction methods, and component placement to ensure a functional and safe electric cooler scooter.
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Gathering the necessary parts
Building an electric cooler scooter from scratch can be a fun and rewarding project, but it requires careful planning and a range of parts. Here is a detailed list of the necessary components you will need to gather:
Firstly, you will require a sturdy frame that can accommodate the cooler snugly while providing ample space for all the other components. The frame should be made from aluminium angle, measuring approximately 40 inches long and 15 inches wide. You can weld this together or, if welding is not an option, simply bolt it together to form a stable structure.
Next, you will need a suitable cooler. Choose a roto-molded cooler that fits perfectly within your frame. Ensure it is durable and of good quality, as you don't want it to tear under the weight of the scooter or during the mounting process. You will also need to drill holes through the cooler to bolt it securely to the frame, so consider using extra-large fender washers inside to prevent tear-out.
The steering system is another critical aspect. You can fabricate most of it from scratch to save costs, but you will need to source specific parts. These include a 5/8" grade 8 bolt for the right steering spindle bracket, and you may also want to add gussets to the front wheel hubs for added strength. Replace the stock bearings with XiKe 4 Pack 99502HNR Ball Bearings (ID 5/8" x OD 1-3/8" x Width 7/16") for improved performance.
For the wheels, you can purchase cheap ones from stores like Harbor Freight for around $7 each. You will need to modify the rear wheel hub for the powertrain, and create two driven wheels for the rear axle. To do this, make keyed sleeves and weld them into two of the wheels. Additionally, the axle should be mounted using aluminium angle and 3/4" bore flange bearings.
Lastly, consider the power source and battery. You can reuse a powertrain from an old scooter, or source a small motor with sufficient torque to propel the scooter from a standstill, even with a fully loaded cooler and adult riders. AGM battery packs can be tucked neatly under the frame, and you can upgrade to Lithium batteries in the future for extended range.
Remember, this list provides a comprehensive overview, and some parts may be substituted or adapted based on your specific design and available resources. Always prioritize safety and wear protective equipment when constructing and riding your electric cooler scooter.
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Assembling the wheels and axles
To assemble the wheels and axles of your electric cooler scooter, you will need to follow these steps:
First, create the spindles that will be used for the front wheel mounts. To do this, take a piece of 1" tubing, add two washers to either end, and secure with a 5/8" bolt through the middle. Weld the washers to the tube and weld the bolt to the side of the tube.
Next, you will need to make the driven wheels that will be attached to the rear axle. To do this, weld keyed sleeves into two of the wheels. Ensure that the axle is square to the frame to avoid issues when driving. Secure the axle using aluminum angle and 3/4" bore flange bearings.
Now, bolt the spindle mounts to the frame, and then attach the spindles to create a rolling frame. Ensure you have the correct spacing between the front wheels and the running boards. You can use heim joints and pipe to create front tie rods, which will allow you to adjust the toe and ensure the front wheels are parallel.
Finally, attach the wheels to the axles. For added strength, you may want to consider adding gussets to the front wheel hubs, as well as upgrading the stock bearings.
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Adding the steering system
Adding a steering system to your electric cooler scooter is a crucial step to ensure smooth operation and control. Here is a detailed guide on how to approach this:
Firstly, source the steering components. You will need a set of handlebars with a mounted throttle for speed control. This will allow you to steer and control the speed of your scooter. If you are adapting an existing scooter, you may be able to use its handlebars and wheel assembly, ensuring compatibility with your cooler's base.
Next, install the handlebars securely. Ensure they are mounted at a comfortable height, allowing for easy steering whether you are seated or standing. This step may involve welding or bolting the handlebars to the frame, depending on your design. Make sure that the handlebars have enough clearance from the cooler box to avoid any interference when turning.
After installing the handlebars, you will need to connect the steering mechanism to the front wheel assembly. This typically involves using tie rods to link the handlebars to the front wheels, allowing them to turn in response to your steering input. Ensure that the tie rods are adjusted properly so that the front wheels are parallel, enabling straight and stable driving.
Additionally, consider adding a steering cooler to your system to maintain the performance and longevity of your power steering fluid. This involves identifying the low-pressure power steering fluid return line and finding an appropriate mounting location for the cooler. Modern oil coolers are efficient and do not require direct airflow, so you can mount it in a tidy, accessible location.
Finally, test the steering system thoroughly. Conduct a test ride and check for smooth steering, proper turning radius, and responsive handling. Make any necessary adjustments to ensure optimal performance. Remember to also test the brakes and conduct a general safety inspection before taking your electric cooler scooter on adventures!
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Mounting the cooler
To mount the cooler, you will need to first ensure you have a frame that fits the cooler snugly. The frame should also be stable and have enough length for all the parts. The recommended frame size is 40" long and 15" wide, made from aluminium angle. You can either weld the frame together or bolt it, depending on your available tools and expertise.
Once the frame is built, you can attach the cooler by drilling four holes through the cooler and bolting it to the frame. Use extra-large fender washers inside the cooler to prevent tear-out and ensure a secure fit.
If you are building a gas-powered cooler kart, as described in one of the sources, you will also need to consider the placement of the axle and ensure it is square to the frame to avoid issues when driving. The front spindle mounts should be bolted to the frame, and then the spindles can be added to create a rolling frame. Ensure you have the correct spacing between the front wheels and the running boards.
It is also recommended to create a 3D model of your design before beginning, to help visualise the parts needed and how they will fit together. This can save time and ensure you have all the necessary components before starting the build.
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Frequently asked questions
The first step is to make a 3D model to help visualise what parts are needed and how they will fit together.
The frame is made from aluminium angle and measures 40" long and 15" wide. It can be welded or bolted together.
The steering system can be fabricated from scratch, excluding the handlebars. You will need a steering spindle bracket, a modified rear wheel hub, and replacement bearings.
Wheels can be purchased cheaply from stores such as Harbor Freight for around $7.
It is important to wear a helmet when riding your cooler kart as it can reach speeds over 25 mph and be very dangerous if not handled properly.
