ElEctric longboard

A guide to building your own electric longboard

Sai Shivani Soundararaj

Dedicated to my brother who helped, supported and guided me throughout the process of writing this book.

ELECTRIC LONGBOARDA guide to building your own

electric longboard

Sai Shivani Soundararaj

TABLE OF CONTENTS

PARTS NEEDED (1)-------------------------------------------------

PARTS NEEDED (2)--------------------------------------------------

TOOLS NEEDED-----------------------------------------------------

INTRODUCTION----------------------------------------------------

Trucks & motor mount Setting up the trucks & motor mount----------------------- Attaching the wheels------------------------------------------Battery casing Preparing the battery enclosure------------------------------ Preparing the battery holders-------------------------------- Setting up the batteries---------------------------------------Motor & drive train Setting up the motor & timing belt-------------------------Electronics enclosure Setting up the ESC---------------------------------------------Wiring Connections & tubing-----------------------------------------Transmitter & receiver setup----------------------------------------Calibration-------------------------------------------------------------Testing------------------------------------------------------------------Charging the batteries------------------------------------------------

SAFETY MEASURES-------------------------------------------------

Table of Contents | 1

3

5

7

9

11 13

15 17 19

21

25

2728 293031

33

PARTS NEEDED (1)

Description

Longboard DH Race 39.5”Paris Style Trucks + ABEC-11 Wheels and BearingsPure-Silicone Wire 10AWG (1mtr) RED Pure-Silicone Wire 10AWG (1mtr) BLACK Container Store Mesh Drawer Organizer Silver 6” x 9” x 2”h36” x 3/4” x 1/6” Thick Aluminium AngleDual e Diagonal Electric Longboard Kit ( Motor Mount Fitment: 63mm RC Brushless Motor )150A High performance Brushless Car ESC HKSS programming card for HK 150A ESC Aerodrive SK3 - 6364-213kv Brushless Outrunner MotorFlightmax 8000mAh 3S1P 30CB6-AC Charger/Discharger 1-6 Cells HK-GT2B 3CH 2.4GHz Transmitter and Receiver w/Rechargable Li-ion Battery Carbon Vinyl StickersVelcro Staps 2 PackScotch Extreme VelcroRubber Neoprene Grommet 3/8in20 Pairs Gold Tone Metal RC Banana Bullet Plug Connector Male Female 4mmMetal Screws #8 5/8inRadio Shack Project Box 2700238 5 1/4” x 3 x 2Black Flex TubingHK-173 Thread Locker & Sealant Permanent (Red)

quantity

1 1

111

21

111

211

12131

12111

Parts Needed (1) | 3

Description

B6-AC Charger/Discharger 1-6 Cells HK-GT2B 3CH 2.4GHz Transmitter and Receiver w/Rechargable Li-ion Battery Heat Shrink Tube 10mm BLACK (1mtr) EC5 5mm Connector (Pair) Peel-n-stick foam tape 10x5inch 4mm thick

quantity

11

1105

PARTS NEEDED (2)

Parts Needed (2) | 5

TOOLS NEEDED

Description

Dremel 4000-2/30 120-Volt Variable Speed Rotary Tool Kit Alpha Fry AT-31604 60-40 Rosin Core Solder (4 Ounces) Hot Max 24171 2-Ounce Soldering Paste Fluz Bernzomatic Butane Flame Torch & Accessory KitBernzomatic Butane RefillHusky 3 1/2” C-ClampTitanium Drill Bit SetDewalt Eye Protection Goggles

quantity

1

1

111111

Tools Needed | 7

INTRODUCTION

It is time to own the streets on an electric longboard. These electric longboards are environmental friendly and are easy to build.

This book has a comprehensive list of components along with assembly instructions. Once you know the basics of building an electric longboard, you can replace the parts with more powerful and stronger components.

This book is meant for people above the age of 14. The electric longboard should be built under strict adult supervision.

Introduction | 9

1

2

Place the trucks on the bottom side at the two ends of the deck. Place the truck with the soldered motor mount towards the front end of the deck, and the regular truck at the rear end. (A)

Align the mounting holes in the trucks with the holes on the deck and screw them using the nut and bolt setup.

Additional Information:• The Motor Mount helps keep the motor and drive

system in place, relative to the wheels. There is tremendous stress on trucks, motor and mount while riding a longboard due to the vibrations. Hence it is critical to have a solid soldered in-place mount.

A : Truck with motor mount in the front end, regular truck at rear end

B : Front view of trucks fixed to the deck

Setting up the Trucks & Motor MountComponents:

• Deck• Trucks • Nuts & bolts

Setting up the Trucks & Motor Mount | 11

1

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3

4

To fix the wheels to the trucks, slide the components onto the trucks in the following order (A) : Speed Ring, Bearing, Spacer, Bearing, Speed Ring. Now place the wheel on this setup and apply firm pressure till you hear a click. This ensures that the bearing setup has locked-in with the wheel.

Fix the wheel with the gear hub on the side with the motor mount (B).The remaining three wheels can be used for any of the other three positions.

Place and tighten the nut. Make sure to tighten the nut just enough to allow the wheels to rotate freely without wobbling. Too tight and the wheels won’t rotate freely, too loose and the wheels will wobble.

Repeat the above steps for all the four wheels.

A : Order of components on the truck

B : Wheel with gear hub on the motor mount side

speed ringspacerbearing

hangeraxle

speed ringbearing nutwheel

Gear hub

Attaching the WheelsComponents:

• Wheels & bearings

Attaching the Wheels | 13

Cut a piece of the carbon vinyl stick about an inch longer than the dimension of the bottom face of the mesh organizer drawer (A). Apply the sticker with firm pressure. Use a hair dryer to heat up the fiber slightly (B); this helps it adhere more firmly. The carbon vinyl sticker prevents too much debris from reaching the batteries

Use an X-Acto knife to trim off the excess sticker.

Line the inside of the cage with the 4mm foam sticker (C). This creates some cushioning for the batteries during possible impact.

Drill two holes on the front side of the cage, one for the wiring and another for the switch. Use a rubber grommet and/or tape to line the sharp edges to avoid damage to the wires. (D)

Additional Information:• The battery casing serves two main purposes: Hold the

batteries firmly in place and protect it from debris and damage. In addition to above, the casing should:

• Providesufficientventilationtoensurethebatteries don’t heat up • Cushionthebatteriestoreducevibrationsandshock • Allowforboardflexwithoutdamagingthebatteries• Themeshcageallowsforventilationandairflow.

1

2

3

4

A : Sticking the carbon vinyl sticker B : Use hair dryer to fix firmly

C : Foam sticker lining the inside of the cage D : Drill holes & tape to line the sharp edges

Preparing the Battery EnclosureComponents:

• Mesh organizer drawer

• Carbon Vinyl sticker

• X-Acto knife• Foam sticker• Driller• Rubber grommet /

tape

Preparing the Battery Enclosure | 15

Preparing the Battery Holders1

2

3

Cut a piece of the 4mm double sided foam slightly bigger than the cage and apply it to the rear end of your deck (A). The purpose of this cushioning is to prevent the battery holders from breaking when the boardflexes.Italsoreducesthevibrationsbeingtransmittedtothe batteries during operation.

Place the three Velcro straps; the two shorter ones on the edges and the longer one in the middle (B) and screw the four aluminum L-plates along the edges. Adjust the plates such that they hold the batteries in place firmly, without squeeze or wobble (C).

Line the mounting screws with foam tape (D).

A : Foam sticker on the rear end B : Velcro straps placement

C : 4 L - shaped aluminium plates D : Lining the aluminium plates with foam tape

Components:

• Double sided foam tape

• Velcro straps• Aluminum L

shaped plates

Preparing the Battery Holders | 17

Setting up the Batteries1

2

3

Place the batteries on the foam tape and fix them in place. Run the wires along the edge of the L-plates (A).

Strap the batteries in place, with no vertical or horizontal movement, using the outer (2 small) Velcro straps (A).

Connect the two batteries in series; connect black of battery 1 to red of battery 2. The red of battery 1 and black of battery 2 are pulled out through the holes. Tighten the central Velcro straps around the cage to hold it in place (C).

Additional Information:• To allow enough clearance from the ground, we place the

batteries side by side instead of stacking them on top of each other.

A : Battery tightened using velcro straps B : Battery series connection

C : Tightening the battery casing

Components :

• Batteries• Connectors• Tape

Setting up the Batteries | 19

Setting up the Motor & Timing Belt1

2

Grind a small flat spot on themotor shaft, for the small gear tosit tightly on it (A). The grub screws on the gear can make better contactwiththeflatspotandhencetheconnectionistighterandmore stable under stress

Fit the motor to the mount loosely (B, C). Then attach the small gear on the mount (D) . Make sure that the grub screws sit on the twoflatspotsgroundontheshaft.

Tip: Use Loctite on the screws (both grub screws and the screws used to connect the motor to the mount) to keep them tight under stress.

A : Grind on the motor shaft B : Side view of motor attached to the mount

C : Top view of motor attached to the mount D : Attaching the gear to the motor

grind on the motor shaft

Components:

• Motor • Screws• Gear• Loctite

Setting up the Motor & Timing Belt | 21

Setting up the Motor & Timing Belt1

2

Push the gear connected to the motor to the right closer to the wheel with the gear (E). Now slide the timing belt between gear on the wheel and the gear connected to the motor.

Once the timing belt is fixed in place, pull the gear connected to the motor on the mount back to place, such that the timing belt is tight, but not too tight (F). Tighten the screws on the mount (using Loctite) to ensure they stay in place.

Additional Information:• The motor and drive train setup are critical components in

your electric longboard setup. The drive train setup is what makes your board move and, as a result, is usually placed under tremendous stress. Hence it is critical to fix the components correctly, ensuring that they stay in alignment at all times. Failure to do so might result in a damaged motor or worse.

E : Pushing the gear near to the wheel F : Top view after the timing belt is fixed

Components:

• Timing belt• Loctite

Setting up the Motor & Timing Belt | 23

Setting up the ESC1

2

3

4

Affixtheinsideoftheelectronicsenclosurewiththefoampad.Markthe positions of the ESC screws and the fan ventilation (A).

Also drill two 3/8” holes on one side; one for the motor wires and the other for the power cables (A). Line the cable holes with rubber grommets to protect the wires (B). Apply the carbon vinyl fiber tape to the outside of the enclosure to give it a better look (B).

Fix the ESC to the enclosure and screw it in using the four screws (C). Make sure the ESC’s switch (thin black & red wires) is fed out through one of the drilled cable holes.

Stick a foam pad to the deck to hold the ESC enclosure (D). The foam pad reduces the vibrations and protects the enclosure from boardflex.Fixthebottomoftheenclosureonthedeckusingtwoscrews (D).

Additional Information:• The electronics enclosure contains & protects the ESC

(electronic speed control) and the receiver circuitry. In addition toprotectingtheelectronicsfromflyingdebrisandvibrations,itshouldalsoprovideitwithsufficientventilationtopreventtheESC from heating up (the ESC is notorious for heating up under heavy and extended durations of load)

A : Enclosure with foam pad and holes drilled

C : Fixing the ESC to the enclosure

B : Lining with tape & carbon vinyl sticker

D : Fixing foam pad and the bottom enclosure

Components:

• Foam pad• Enclosure• ESC • Driller• Rubber grommet• Carbon Vinyl tape

Setting up the ESC | 25

Connections & Tubing1

2

3

4

5

Connect the black and red wires form the ESC with the black and red wires from the batteries by soldering a connector between them. (A)

Solder the 4mm Banana Bullet Plug Connector Male to the ends of the blue, orange and yellow wires coming from the ESC. Solder the 4mm Banana Bullet Plug Connector Female to the ends of the three black wires from the motor. (A)

Connect the switch from the ESC to the ch1 or ch2 on the receiver.(B)

Slide a small piece of the heat shrink tube around the black wires. Then connect the three black wires with the red, yellow and black wires in any order and bring the heat shrink tube at the connection. Heat the shrink tube a bit so that it shrink to hold the connections strong. (C)

Place the receiver inside this box. The instructions for this are on the next page. Fix the enclosure (containing the ESC) in place using the four screws. Enclose the wires inside tubing to the protect it from debris and prevent it from getting caught during travel (D). Use a wire clamp stuck to the deck using industrial strength Velcro to hold the excess tubing in place.

Additional Information:• Allcomponentsshouldhavesufficientgroundclearancetoride.

A : Connecting the ESC with the Batteries

C : Connecting the Motor & the ESC

B : Connecting the Receiver with the ESC

D : Enclosing the connections

Motor & ESC connection

ESC & Batteryconnection

ESC & Receiver connection

Components:

• Connectors• Receiver• Heat shrink tube• Tubes• Wire clamp

Connections & Tubing | 27

Calibration | 29

Transmitter & Receiver Setup CalibrationThe transmitter and receiver should be factory paired

Connect the ESC to Channel 2 of the receiver. Our ESC has a BEC (battery eliminator circuit) and is able to provide power for operating the receiver. Hence there is no need of an external power source.

When you turn the switch on, the receiver beeps 6 times to indicate the cell count of your batteries. Press the throttle on your transmitter all the way down and wait for a beep. Press the throttle all the way down and wait for your beep.

Your Tx-Rx pair is now calibrated. Turn off the Rx and Tx and turn on again.

Additional Information:• Always turn on the Tx before turning on the Rx and always

power off the Rx before turning off the Tx. This ensures that your setup is always calibrated correctly.

Components:

• Transmitter• Receiver• ESC

1

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4

You can calibrate the ESC to adjust various settings for your motor. You will need a programming card for this.

Connect the programming card to the ESC wire (the same wire that attaches to the Receiver). The following are ideal starting values:

• Voltage Cut-Off: 3.4 V/Cell• Running Mode: Forward without Reverse• Motor Timing: Normal• Initial Acceleration: Low• Throttle Percent Reverse: Not needed• Throttle Limit: 30% (affects top speed of your board. Start low

and increase gradually as you gain more practice)• Percentage Braking: 50%• Percent Drag Brake: 0%• Motor Rotation: Normal• Neutral Range: 5%

Components:

• ESC• Programming card

1

2

Charging the Batteries | 31

Testing Charging the BatteriesMake sure to test your setup at home before taking it to the road. Ensure that all wires are properly soldered and insulated.

Check to make sure your Tx-Rx is appropriately calibrated and works as desired

When you test it on the road, start slowly. Always kick start (i.e. push with your feet while starting). This increases the life of your battery, motor and drive train setup.

Make sure your motor, ESC and battery don’t overheat. This should not be the case unless you exert the setup on an uphill or rough terrain.

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4

We use Lithium Polymer (LiPo) batteries since they offer the best charge density for the price. However, they pose a fire hazard.

Take extreme care while charging your LiPo batteries. You need a special balancing LiPo battery charger for charging your batteries. Always ensure that the settings on your charger match your battery’s configurations.

While charging the battery and the charger will get hot. Always place themon ahard,non-flammable surface such as a concretefloor. Never charge on a carpet. Never leave charging batteries unattended.

Components:

• Batteries• Battery charger

1

2

3

SAFETY MEASURES

Safety Measures | 33

• Always wear protective equipment such as helmet, wrist guards, knee pads and elbow pads when longboarding.

• Wearflatshoeswhenriding.• The electric longboards are pretty fast, so accelerate and break gradually.• Do not attempt longboarding tricks until you are familiar with the

longboard’s speed and riding areas.• Donotchargethebatteriesonacarpet.Placethemonanon-flammablesurfacewhile

charging.• Make sure that your state/federal/local laws allow you to use electric

longboards for commuting purposes. In most of the states, longboards are considered equal to pedestrians.

You can now rely on your longboards for commute and for some fun. Electric longboards can be the first step towards changing the modes of transportation.

Why walk when you can longboard?

4130927813129

ISBN 978-1-312-41309-290000