Otis Singleton
Converting a scooter to electric can be a fun DIY project, but it requires some work and money. It involves taking an old scooter and transforming it into an electric-powered vehicle. The process includes stripping down the scooter to its chassis, removing the internal combustion engine parts, and modifying the body. The key components of an electric scooter are the frame and motor, with two main types of motor drives: belt/gear driven or direct drive (hub motor). Those interested in converting their scooter can opt for a brushless hub motor, which offers a great power-to-cost ratio as they were designed for hoverboards and mass-produced. While it is possible to buy an electric scooter for a few hundred dollars, building your own can be a rewarding experience for those who enjoy tinkering and creating something unique.
| Characteristics | Values |
|---|---|
| Purpose | Gain experience in building something from scratch |
| Primary Components | Scooter frame and motor |
| Motor Types | Belt/gear driven, direct drive, or hub motor |
| Motor Choice | Brushless hub motor from a hoverboard |
| Motor Placement | Front to keep the hand-controlled rear disc brake functional |
| Motor Mount | Must support the user's weight and motor torque |
| Wheel Assembly | Cut from hex extrusion |
| Frame Material | Aluminum |
| Design Software | Autodesk Inventor |
| Design Components | L-shaped piece connecting handlebar actuation to motor; clamps motor to base |
| Battery Mount | Raise the deck or mount to the handlebar pole |
| Battery | Buy or build to fit the available space |
| Additional Components | BMS + motor controller, hub motor, charger |
| Cost | Varies; approx. $75 for odds and ends, $50 for a charger, $40 for battery components, $50 for BMS + motor controller, $35 for PCBs |
| Alternative | Purchase a Xiaomi Mi scooter for around $400 |
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What You'll Learn
- Sourcing parts: buy old, non-working scooters or use hoverboard parts
- Scooter frame and motor: choose a belt/gear or direct drive
- Battery mounting: raise the deck or mount to the handlebar pole
- Engine assembly: mount the motor on an adapter plate
- Wheel assembly: cut with a band saw and design a motor mount
Sourcing parts: buy old, non-working scooters or use hoverboard parts
One of the most cost-effective ways to source parts for your electric scooter conversion is to buy old, non-working scooters or use hoverboard parts.
You can find broken hoverboards for sale online, such as on eBay, and salvage the working parts. For example, you might find that the motherboard is faulty, but the battery, motors, and charger are functional and can be used for your build. You can also source an old kick scooter to use as the base for your project, which will be much cheaper than buying a new one.
When looking for a hoverboard to use for parts, consider the wattage and voltage of the motor. Most hoverboards have 250W or 350W 36V motors, but you may want to opt for a higher voltage motor if you're looking for more speed.
In addition to the motor, you'll also need a throttle, an LCD display, and a speed controller. These can often be purchased online or salvaged from other devices. Keep in mind that you may need to replace some connectors to ensure compatibility with your other parts.
By sourcing used or broken parts and doing the labour yourself, you can significantly reduce the cost of converting a scooter to electric power.
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Scooter frame and motor: choose a belt/gear or direct drive
When it comes to choosing a motor for your electric scooter, you have a few options: belt drive, gear drive, or direct drive. Each has its own advantages and disadvantages that you should consider before making a decision.
Direct drive motors are larger and heavier than geared motors. They are also more expensive due to their larger size. However, they offer smoother operation because there is no friction between moving parts, making them more silent. They are also low-maintenance since there are no gears that need regular servicing, and they tend to have longer lifespans. Direct drive motors are a good choice if you plan on riding at higher speeds as they offer constant power without gear ratio limits, resulting in greater efficiency. Additionally, they can create power through regenerative braking, which can save battery life.
Geared hub motors, on the other hand, are smaller and lighter, making them easier to integrate into compact and lightweight frames. They are excellent for low-speed performance, providing better torque for stop-and-go urban riding and stronger climbing ability on hills. However, the gears may become noisy and hot with continuous usage.
Belt drive systems, like geared drive systems, use a small motor and a belt and pulley system to generate force feedback. This setup allows for the use of low-cost motors, making belt drive systems a more affordable option. However, the trade-off is a loss of force feedback detail and less accuracy in the feedback. Additionally, belts can wear out or stretch over time, resulting in product failure.
When choosing between belt, gear, or direct drive for your electric scooter, consider factors such as your budget, desired speed, torque requirements, maintenance preferences, and the type of frame you are working with. Each type of drive system has its own advantages and will suit different use cases, so it's important to evaluate your specific needs before making a decision.
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Battery mounting: raise the deck or mount to the handlebar pole
When it comes to mounting the battery for your electric scooter conversion, there are a couple of options to consider: raising the deck or mounting the battery to the handlebar pole. Both methods are viable options, and each has its own advantages and considerations.
Let's start with raising the deck to accommodate the battery. This option typically involves lifting the platform of the scooter, creating additional space underneath to house the battery. This method can provide a more streamlined appearance and keep the battery protected within the structure of the scooter. However, it may require more significant modifications to the scooter's deck, potentially affecting its structural integrity and aesthetics. It is important to ensure that any modifications made are secure and do not compromise the overall stability and safety of the scooter.
On the other hand, mounting the battery to the handlebar pole presents an alternative approach. This method involves attaching the external battery externally, usually at the junction between the handlebars and the platform. This option can be relatively easier to install and may not require extensive modifications to the scooter's structure. It provides easy access to the battery for monitoring and replacement. However, it is important to consider the potential impact on handling dynamics. Mounting the battery higher up can slightly affect the scooter's manoeuvrability and steering feel due to the additional weight distribution.
The choice between raising the deck or mounting the battery to the handlebar pole depends on several factors. These include the available space under the deck, the size and shape of the battery, and the desired aesthetics of the final product. It is crucial to strike a balance between functionality and the structural integrity of the scooter. Before proceeding with any modifications, carefully assess the scooter's design and ensure that the chosen battery is compatible with the selected mounting option.
It is worth noting that some scooters, like the Xiaomi and Ninebot models, offer the option to mount the battery at the platform without significantly affecting stability. This approach can provide a more seamless riding experience. However, for other scooter models, mounting the battery on the handlebar post might be the preferred or only viable option. Always refer to the specific characteristics of your scooter model and the battery manufacturer's instructions for the best results.
Ultimately, whether you choose to raise the deck or mount the battery to the handlebar pole, ensure that the installation is secure and stable. Consider seeking guidance from experts or individuals with experience in electric scooter conversions to ensure a safe and efficient modification process.
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Engine assembly: mount the motor on an adapter plate
To convert a scooter to electric, the engine assembly process involves mounting the motor onto an adapter plate. This is a crucial step to ensure the motor is securely attached to the scooter's frame. Here's a detailed guide on how to approach this:
Firstly, it's important to select an appropriate adapter plate that matches the motor and scooter specifications. In this case, an adapter plate made from aluminium can be used to fix the motor on the fan side of the crankcase. This provides a stable base for the motor to be mounted.
The next step is to prepare the engine for assembly. This involves removing all internal combustion engine parts, including the head block, piston, crankshaft, air filter, and magneto assembly. Ensure that the engine is completely stripped down and only the chassis remains.
Now, you can begin the process of mounting the motor onto the adapter plate. Start by aligning the motor with the adapter plate, ensuring that the bolt patterns match. It's important to maintain parallel and square lines during this process to facilitate easy mounting. You may need to create through holes on the transmission side and threaded holes on the motor side of the adapter plate for secure fastening.
Once the motor and adapter plate are aligned, you can insert the well-greased nylon coupler between the shaft and the motor. This ensures a smooth connection and reduces friction.
Finally, bolt the motor firmly onto the crankcase body of the engine. Make sure all bolts are tightened securely to prevent any vibrations or movement during scooter operation.
With the motor mounted on the adapter plate, you can now proceed to connect the gears between the motor and driveshaft. This step ensures that the power generated by the motor is transmitted effectively to the scooter's wheels.
By following these steps, you will have successfully mounted the motor onto the adapter plate, completing a crucial stage in converting a scooter to electric power. Remember to refer to visual guides and seek assistance if needed, as this process requires precision and mechanical expertise.
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Wheel assembly: cut with a band saw and design a motor mount
Converting a scooter to electric involves several steps, and one of the most challenging parts is the design of the wheel housing and motor mount. The process begins by cutting the wheel assembly with a band saw. This step requires precision and accuracy to ensure the structural integrity of the scooter. The band saw is a versatile tool that can cut through various materials, including wood, mild steel, and aluminum.
After cutting the wheel assembly, the next step is to design and fabricate a motor mount that can support the weight of the user and the torque of the motor. This is a crucial step as it ensures the safety and performance of the electric scooter. The motor mount is designed to hold and secure the motor in place while providing a stable base for the scooter.
In the given example, the author of the conversion guide used a large scrap piece of aluminum to create a frame for the motor mount. This frame is then clamped securely with four machine bolts and a small stock piece with through holes. The design consists of two main pieces: an L-shaped piece that connects the handlebar actuation to the motor, and another piece that clamps the motor to the base using bolts.
To ensure the stability and safety of the motor mount, it is essential to consider the weight distribution and torque generated by the motor. The motor mount must be able to withstand the forces exerted during acceleration and turning. Additionally, the design should allow for easy access to the motor for maintenance and repairs.
The process of converting a scooter to electric involves a combination of mechanical and electrical skills. It requires careful planning and consideration of the scooter's structure, weight distribution, and performance requirements. By following guides and with the right tools and knowledge, it is possible to successfully design and fabricate a functional and safe electric scooter.
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Frequently asked questions
The scooter frame and motor. There are two main types of motor drives for DIY scooters: belt/gear-driven or direct drive, such as a hub motor.
A spot to mount a battery, a battery to fit that space, a BMS + motor controller, and a hub motor that fits dimensionally. You will also need to buy a charger.
Buying an electric scooter like the Xiaomi Mi version for around $400 is likely more cost-effective than building your own. However, building your own scooter can be a rewarding experience.
The design of the wheel housing. If using a hub motor, the motor mount must support the weight of the user and the torque of the motor.
