Beatrice Lang
Electric skateboards can be expensive, with prices ranging from €500 to over £1200. Building your own electric skateboard is a great way to save money and explore your passion for engineering and skateboarding. It involves mechanics, electronics, and design, and can be a multidisciplinary art form. The process is relatively easy for hardware but challenging for software. The final performance depends on the compatibility of the software with the battery and motors. When building your own electric skateboard, it's important to consider factors such as the motor, speed controller, battery, and enclosure. You can also seek advice from online forums and purchase kits to make the process easier.
| Characteristics | Values |
|---|---|
| Speed | 20-45+ mph |
| Range | 6-20+ miles per charge |
| Hill climbing | 20-30% inclines |
| Braking | Wireless handheld remote controller |
| Motor | Single or dual setup |
| Motor type | Brushless out-runners for rc planes |
| Motor KV ratio | 100-300 KV |
| Battery | 10s battery |
| Battery current | 95-135 amp |
| ESC | High-amp speed controller |
| RC | From the same supplier as the ESC |
| Deck | Longboard |
| Trucks | Top-mounted |
| Wheels | Large diameter, medium softness |
| Enclosure | Good airflow, sturdy, secure |
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What You'll Learn
Choosing the right components
When it comes to choosing the right components for your electric skateboard, there are several key factors to consider. Firstly, decide on the type of deck you want. A longboard deck offers more stability, a smoother ride, and more space for electronics, whereas a standard skateboard deck provides a more compact and manoeuvrable option. Consider the trade-off between stability and agility when making your decision.
The next important component is the motor. You can choose between a single or dual motor setup. Single motor configurations are generally cheaper, with one larger low kv motor being sufficient for average commuting and hill climbing. On the other hand, dual motor setups provide significantly more power and climb hills with ease, but they come at a higher cost. When selecting a motor, ensure it has high power and torque, and consider brushless out-runners typically used for rc planes. Look for motors with low kv values, such as the Turnigy sk3 213kv or the NTM prop drive 270kv.
Another critical component is the Electronic Speed Controller (ESC). The ESC controls the speed of the motor and is a key element in determining the final performance of your electric skateboard. Ensure you get a good quality ESC that can handle very high amps, typically identified by "HV" in the name. It is recommended to choose an ESC that is compatible with your chosen motor and batteries to avoid optimisation issues and potential problems like incorrect speed displays, uneven braking, and acceleration algorithm errors.
In addition to the ESC, you will need a reliable power source in the form of batteries. Opt for batteries with a high current rating, such as 95 amps or higher, to ensure sufficient power delivery to the motor. Consider the balance between voltage and compliance with the motor-rated voltage, as this will determine the output power. To protect your batteries and other expensive components, design or purchase a solid enclosure with good airflow, sturdy construction, and a secure way to hold the electronics in place.
Lastly, consider the wheels and trucks. For wheels, opt for a relatively large diameter and medium softness for a smoother ride. Some wheels, like the Orangatang Kegel, come with plastic hubs that are ideal for mounting the pulley wheel. For trucks, consider the shape and design to ensure compatibility with your chosen motor mount. Top-mounted trucks provide more room underneath for the electronics enclosure and motor.
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Assembling the parts
Choosing the Right Parts
Before you begin assembling, it's crucial to select compatible and high-quality parts for your electric skateboard. This includes the board, trucks, motor, motor mount, batteries, speed controller (ESC), and connectors. Ensure the parts match in terms of voltage, current, and compatibility. For instance, a high-current single motor setup will require a large motor.
Preparing the Motor and Pulleys
Attaching the pulleys is a critical step. Ensure the pulleys and wheels align correctly. You may need to adjust the bore diameter of the smaller pulley if it's too small for your wheels. Secure the pulleys with the provided screws and bolts, tightening them appropriately.
Mounting the Motor
The motor mount allows you to attach the motor to the skateboard trucks. Ensure the mount is compatible with your truck type. Use bolts to securely attach the motor to the mount, and consider using Loctite to prevent the bolts from loosening due to vibrations.
Battery Enclosure
To protect your batteries and electronics, create a solid enclosure with good airflow and sturdy construction. Sketch out your components on paper to plan a compact layout. Use mesh for airflow, double-sided foam for securing certain parts, and screws to attach the enclosure to the deck.
Wiring and Electronics
The electronics involve soldering and connecting parts according to a wiring diagram. Ensure you have the correct connectors and plugs for your battery setup. Follow instructions carefully, especially when dealing with high-power components like the speed controller.
Testing and Fine-Tuning
Once assembled, test your electric skateboard thoroughly. Check for loose bolts, especially after the initial ride, as vibrations can cause them to loosen over time. Fine-tune your setup as needed, ensuring all components are secure and functioning optimally.
Remember to wear protective gear when riding your electric skateboard, and always follow safety guidelines.
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Customising the design
Firstly, consider the deck material. You can opt for carbon or bamboo, depending on your preference. The deck is an important aspect of the design, as it needs to be solid with little flex and top-mounted to accommodate the electronics enclosure and motor. You can also choose the shape and design of the trucks, ensuring they are compatible with a motor mount.
The wheels are another key component. Select a relatively large diameter with medium softness for a smoother ride. You can also choose between street or all-terrain wheels, depending on the type of terrain you plan to ride on. If you opt for a 2-in-1 board, you can easily switch between different wheel types to suit various environments.
The motor setup is an important decision. A single motor setup is usually sufficient for commuting and is more cost-effective, but dual setups provide more power and climb hills with ease. Choose a motor with high power and torque, and consider the current requirements to ensure it matches the battery and ESC setup.
The ESC (electronic speed controller) is a critical element that combines the functioning of the battery and motor. Ensure it can support very high amps, and consider the total loading power to match the battery and motor performance.
Finally, design a sturdy enclosure to protect your batteries and electronics. Consider airflow, construction, and a secure way to hold the components. You can use materials like brushed aluminium and carbon fibre vinyl to enhance the aesthetics and functionality of your enclosure.
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Understanding the basics
The electronic speed controller (ESC) is at the heart of an electric skateboard's operation, serving as the bridge between the rider's input through a handheld wireless remote and the motor's output. The ESC combines the workings of the battery and motor, and a good-quality one will be able to support very high amps. The right ESC will depend on the type of motor and battery you choose. The RC (remote control) should ideally come from the same supplier as the ESC to avoid optimisation issues.
The motor is another key component. Brushless DC motors are recommended for electric skateboards because of the power they can deliver in a small package. The KV-ratio is an important specification to consider when choosing a motor. KV stands for rpm/Volt applied to the motor. For example, applying 10 volts to a 190KV motor will result in 1900 rounds per minute. The higher the KV, the lower the torque (force) the motor can output. The usable KV-ratio for electric skateboards is between 100 and 300 KV.
The type of deck you choose is also important. A longboard deck will give you more stability and a smoother ride than a skateboard deck. You will also need to consider the shape and design of the trucks (the axle) to ensure a motor mount can be made for it. The wheels should have a relatively large diameter and medium softness for a smoother ride.
Finally, to protect your batteries and other expensive parts, you will need a solid enclosure with good airflow, sturdy construction and a suitable way to hold the electronics securely.
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Testing and troubleshooting
Battery Issues:
- Battery Won't Charge: Start by checking the power supply. Ensure that the charger is plugged into a functional outlet. Consider testing the outlet with another electronic device to rule out any power source problems. Verify that you are using the correct charger, as an incompatible charger can damage the battery. Inspect the charging cable for any signs of damage, such as frayed or bent wires, and replace it if necessary.
- Dead Battery: If your skateboard won't turn on, check if the batteries are properly connected to the rest of the circuit. Inspect all the wires in the circuit, especially those coming from the wheels, as they may have become disconnected due to ride stress or rough handling. Reconnect or replace damaged wires, being careful not to cause further damage.
- Battery Lifespan: Regularly check the remaining capacity of your battery. If the original capacity falls below 60% to 80%, consider replacing the battery. To prolong battery life, avoid overcharging or over-draining it.
Motor and ESC (Electronic Speed Controller) Concerns:
- Motor and ESC Compatibility: Ensure that your motor can handle the selected current. A very high current, such as 95 amps, may require a large motor. Balance the voltage with the motor's rated voltage, as V (voltage) and AMP (current) determine output power.
- ESC Selection: Choose an ESC that can handle high amps and is compatible with your motor and batteries. Look for ESCs identified by HV (High Voltage) in the name. Consider purchasing from a seller who provides a kit with compatible parts, such as Bruno at alienpowersyetem.
- ESC Programming: If you're using a VESC, take advantage of the Setup wizard, which simplifies the programming process. Ensure you enter correct telemetry data, as incorrect values can lead to inaccurate readings.
General Troubleshooting Tips:
- New Parts: If you've recently added new parts, such as a charger or wheels, remove them temporarily. If the skateboard responds, the new parts may be the source of the issue.
- Warranty Claims: If you encounter battery issues and your skateboard is still under warranty, don't hesitate to claim it. Contact the manufacturer's customer service for assistance.
- Safety First: Always prioritize safety when testing and troubleshooting. Be cautious when handling batteries and electrical components, and avoid riding in unsafe conditions.
Remember, building an electric skateboard can be a complex process, and issues may arise. Stay patient, methodical, and safety-conscious throughout your testing and troubleshooting journey.
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Frequently asked questions
Motors with high power and torque are suitable for electric skateboards. Brushless out-runners for rc planes are commonly used. You need one with a low kv such as the Turnigy sk3 213kv or the smaller NTM prop drive 270kv.
The speed controller combines the working of the battery and motor. You need a speed controller that can support very high amps. These are usually identified by HV in the name.
Most people use Lithium Polymer (LiPo) batteries. The pack configuration is also important, e.g. 4S1P means 4 cells in series forming one pack. The mAh rating indicates how long it will provide power, and the C rating is the discharge rate.
Attaching the pulleys is an important step. Ensure the screws and bolts provided fit your wheels. You may need to drill bigger holes in the pulley if the inside bore diameter is too small.
The vibrations from the skateboard can cause bolts to loosen. Loctite is an adhesive that can be used to prevent this issue. Medium strength Loctite is recommended to prevent loosening while still allowing for the removal of screws.
