Well let me start off by saying I’ve been lurking around here for a little while gathering information and ow I believe it’s time to contribute.
First a little background. I have a Master’s degree in Mechanical Engineering so it would be a fair statement to say I’m a bit nerdy. I’ve always been interested in building pretty much anything and spend the majority of my spare time in my wood shop making furniture. A few months ago I was introduced to electric skateboards by Casey Neistat and the Boosted Board. While I found the idea to be a novel one I found the board to be lacking. So after a few short minutes of googling I found that it wouldn’t be very hard to build my own to the way I wanted it.
Now there seems to be two thoughts to this process, build from scratch and assemble from parts. With my first born daughter still an infant I have more money than time so I chose the latter approach while fabricating what I could.
To start off here is my BOM with associated prices and comments for those that are interested.
Deck: Loaded Truncated Tesseract $230
Trucks – Bears – wheels - risers: Callibur 2’s $54 Reds bone swiss $50 Orangatang Kegels 83a $60 Luxe 0.5 inch $4
Motor & mount: Alien 6355 HEV 190 kv x2 $73 ea Alien drive longboard diy 63mm kit x2 $145 ea
Electronics: Nyko Kama remote $15 DIY Electric skateboard VESC x2 $90 Parallel XT90 connector $9 CAN bus connector $7
Battery: Battery Bro Samsung 25R5 x50 $3.68 ea Dxsoul diy 4 slot 18650 battery holder x10 $32 Mean Well HLG-150H-42A Power supply $62
MISC: Wire, nuts, screws, ect. $50
Needless to say this project coming in at a total of $1373 was way more than my expectations in the beginning. But everything always costs more and takes longer than one would think, and I still came in under the price of a Boosted Board.
A few comments on why I chose certain items, to start off with the deck was for the simple reason that it is a tried and true deck that is compact and can handle speed. I went with Alien’s mounting kits because of all the others I looked at these appeared to be the better engineered, with minimal stress concentrators and well machined. I went with DIY’s VESCs because after scouring the forum they had the least complaints for the best price. Battery Bro was able to get me a decent price for a bulk buy of 50 cells, however I will say that shipping was a nightmare. It took well over a month to get the cells despite the fact that I paid extra to have 3-5 day air shipping and when I received them I was missing some additional items I had ordered, so it took another 2 weeks for them to fix it. I will say they refunded me for the items that were missing in the first package but it was still a disaster and I don’t think I would use them again. The battery charger I chose is not actually a charger, it’s an LED power supply. However it has a customizable output voltage from 37 to 47 volts and a max amperage setting up to 150 watts total output. So I set the voltage to 41.5v and 3.6A, I don’t use a BMS for reasons that WhitePony has outlined and the charger works quite well. It won’t charge the cells to fast due to the max amperage setting and as battery voltage approaches supply the current draw tappers off to zero. But enough words let’s get to some pictures.
First up are the Alien parts, and while the quality is good I found the finish to be a little lacking, there were a number of burs on the Kegel adapters that had to be filed for proper fit.
Next is the 32T HTD5 pullley and as you can see more burs from manufacturing
Next up came the battery build, I decided to go with these 18650 sleds that were only $3.20 a piece and modify them. starting with the removal of the leads and parallel connections.