X6 - A board with a range of over 70km on a single charge
It’s time to post a description and photos from my last build, a board equipped with a gear drive
Parts list: Restless Mantis Warrior 33" Evolve Trucks ABEC 107 Racerstar 5065 140kv 10S4P Samsung 30Q Turnigy SK8-ESC V4.12 Benchwheel DIY Remote & Receiver Enclosure Evolve 2 gen Bluetooth module and metr app Gear Drive
At the beginning I want to apologise for my English, a foreign language isn’t my strong point
Undoubtedly my description will have some mistakes … but you must forgive me… 
DECK
I’m obsessed with the look so I bought 3 decks before I chose the final one
- Kebbek Smoothcut 37
- Jet Invasion Voyager-X
- Restless Mantis Warrior 33"
Restless Mantis Warrior 33 had (in my opinion) the perfect proportions for this compilation so I chose this deck
ENCLOSURE
At the beginning I wanted to make a modular enclosure so that she could bend with the deck I designed encloure made of many pieces that can be combined with each other. Segments (individual parts of the housing) I printed on a 3D printer My enclosure was flexible but not hermetic. Elements made on a 3D printer are also less durable than injection molded parts
I started looking for a casing designed for the board.
I wanted the housing to be durable, hermetic and low … and I found the EVOLVE 2 gen enclosure 
The disadvantage of this enclosure is a small space inside (I could not fit BMS) The advantage is compact dimensions and high durability.
Battery
I chose Samsung 30Q batteries from which I built a 5-segment 10S4P package.
The battery capacity is 432Wh (12Ah), discharging current 60A I wanted to mount the BMS 60A 10S with a Bluetooth module, but this BMS did not fit into the Evolve enclosure
ESC
I had three types to choose from
- FVT Dual 120A, 12S
- Turnigy SK8-ESC V4.12 (VESC 4.12)
- FOCBOX
The FVT Dual 120A, 12S seemed to me the best choice, it was the smallest, it had a built-in switch and passive cooling
However, VESC has much more configuration options and gentler brakes, which is why I decided to use VESC 4.12
Theoretically, along with two VESCs, I would fit BMS inside the enclosure, unfortunately it would be very difficult to implement
Foxbox seems the best choice but I have assigned this ESC to another project (about it at the end)
Remote & Receiver
I chose the Benchwheel DIY Remote & Receiver, it is ugly and not ergonomic, but it is well done, works perfectly and is reliable.
Motors
I chose the "Racerstar 5065 BRH5065" motors for two reasons:
- I designed the direct drive as an upgrade for Evolve boards
- I wanted to use a motor with a small diameter, so that the clearance between the drive casing on the road surface was large
After the first tests, the motors proved to be a great choice, The motors are small but have a large power reserve, they are very well made. The board has a very large acceleration, speed over 40km / h and most importantly a large range. They are also one of the cheapest motors, so they have an excellent value for money
Gear Drive
The idea of building a gear drive for Longboard he suggested to me @Powadangaboards
He asked me if I could do something like that
I did not want to do the same myself, so I did it my way
@Powadangaboards also sold me EVOLVE trucks for which I am very grateful to him
The first prototype was made in February 2018, later, I built several more versions, the final one was created in August and is being tested all the time.
Final version of the gear drive
The drive has a 1: 2 gear ratio, and is designed for 140-150kV motors, Evolve trucks and 97-107mm diameter wheels
The greatest advantage of the drive is the low friction of the toothed gear, the drive is more efficient than the belt transmission. The drive housing is waterproof and dustproof
The disadvantages are the large diameter of the drive (small clearance) and louder work, but I like this sound
The drive’s efficiency is confirmed by tests. The parameters of the drive are measured by Transmitter METR (older type) + application on android
@rpasichnyk has created a great tool,
Without METR, the gear drive tests would be difficult to make, now I introduce small changes in the design of the drive and after driving a distance of a few kilometers I see the effects.
In September, I traveled 71 km on one charge,
My board has a 10S4P battery pack built with Samsung 30Q, so it has only 12Ah
Below are the data from VESC Unfortunately, at the last 8.5 km, the METR has stopped sending telemetry data, only data GPS from the phone’s
These are two measurements from the same day
I think that METR sends data only from one motor, because METR shows me that my battery pack 12AH 10S is 185Wh (5.08Ah) so some data (current, battery capacity) needs to be multiplied x 2
Here, other tests from round trip on a distance of 2km
Energy consumption is about 0.12 Ah for 2km
Assuming the battery is 5.08 Ah, the board should cover a distance of over 80 km
Of course, the ride is very economical, driving with small acceleration at a speed of about 20km/h, but I weigh about 90kg + the weight of the board 10kg together is around 100kg, so the total weight is not small
Finished board
Below are two videos of tests …
In the first film the microphone amplifies the sound … in reality it is quieter
In the second film, the intensity of the sound is more realistic, even a rooster can be heard in the background.
What’s next ???
- Now I design a gear drive for pneumatic wheels for this board. I built the first prototype but I still have a lot of work ahead of me
- I’m starting construction of the second board with a 10S6P battery pack built from Samsung 35E batteries - expected range - over 100km Description of the construction soon…
I’m looking your pic and following this since summer, You made a crazy work !!
let me know how the bearing turns out for you!