this spring a friend of mine I haven’t seen for a while told me that he is driving around over there with an electric skateboard going 45 kph with a range of 35km. I immediately got hook up on the idea of driving around and getting more independent from bus schedules. I don’t have a car but use public transport a lot so it had to be small enough to carry around. I wanted to use my old Element Jeremy Wray deck which I recently transformed into a cruiser board with 3d printed TPU riserpads and longboard wheels. It should be able to be used like a unmotorized skateboard in case police gets suspicious or power runs out. I did a quick search and ended up ordering a cheap 70mm hub motor kit on ebay, sold by a absolutely clueless seller :D.
In the picture I already installed a 3d printed PU (from TPU). I ordered a custom 10S4P Battery made of Samsung 25R cells from someone building these professionally (including BMS) and when it arrived I could not wait to try it out and taped everything together for a test run. During this test run I encountered strange behaviour: In slow mode, everything was fine, but seriously, who wants to use that apart from getting used to driving? In medium mode there was random stuttering in between but it was mostly usable but in fast mode I had stuttering, immediate full throttle and stuff like that so something was obviously wrong. During that time I started doing research over here btw, which helped me pin down the problem. It had to be the ESC so I ordered one from diyeboard which worked perfectly. I taped everything together and already had a lot of fun
when after one bigger trip with my girlfriend one motor started scrubbing at the magnets. I’ll never buy cheap stuff from ebay again Now I was already hooked up 100% so I had to get replacement hubs. I ordered the 70mm hub kit from diyeboard but when It arrived it revealed a bit of a problem: They are longboard style trucks but everything I already planned was based on regular trucks. (The ebay hubs were Maytech style so I cut my trucks the way the hubs fit with their rectangular shaft) The new trucks made turning way too sensitive so I had to move them one hole-distance each apart.
Now I was in love with this hobby: The new motors were so quiet and powerful, speed was a little lower (25kph compared to 28kph with the previous ones) but it felt so much better, perfect
Time for the casing… At work I had the opportunity to get the deck laserscanned with high precision:
I designed a case perfectly aligned to match the board shape for 3d-printing:
but my printer is way too small so I had to depend on others… I hate it the printers at work were all not operable so I had to think of alternatives. I almost bought a CR-10 5S with 50cm build space. With that one I could print it in one piece but it would have been a waste of money since I mostly print smaller parts which can be done better with the fab mini. This forum finally gave me the solution: Kydex. I read a bit and after that I ordered a 30x60cm piece. The delivery gods were angry at me so I waited 3 weeks for it after which the seller did some research after which it was back on track. In the meantime I ordered another one to get the case started but with this there was some delay too Like there was a grudge on my whole project
While waiting I worked on the lights:
They are driven by the main battery, I found a LED driver with up to 56V input and 350mA output.
They’re still a work in progress (right now I don’t have them assembled to the deck at all, I have to redo them first)
After working on the lights I started modelling a bed for the batteries since the board has strong concave that needs to be corrected so the batteries won’t stretch. I printed it in 8 pieces on my fab mini with TPU and puzzled them back together.
When the kydex arrived I already had a wooden body prepared for it:
So i could start immediately when the delivery guy came by I placed a thermotransfer pad between ESC and the aluminium heatsink plus I added a real heatsink on top of it. The plan was to cut a hole in the case for the real heatsink and make the surrounding area waterproof.
This V1 build worked like a charm until the board broke. It looked like swiss cheese all over so when I accidentally hit a really evil edge it cracked RIP my old friend
After that I instantly ordered a new deck (Sale, glas fiber coated) and tried to transfer everything to it but I wasn’t aware of the non standardized truck distance. I was in a hurry and did a really dirty job to get it running at all costs so after that one I ordered a new deck to do it once again right
The green deck is for my upcoming project, its still a regular deck but slightly larger (33.5x8.5 inch). I’ll countersink(?) a battery and electronics bed and cover the whole thing with carbon. The shape will also be changed slightly depending on the new 90mm hub motor trucks (this time with replaceable pus).
Thanks for watching,