(Ongoing)

Electric Mountainboard Build (ROAM)

Abstract
The electric mountainboard project was started so I can not worry about cracks in the
streets and the ability to go off-road. This is a dual E-MTB build. Using my skills in SolidWorks, I
modeled the board and its components from pictures and actual parts to then make the mounts and
enclosures. The first test out on the sand was a great success. Nothing failed and everything
(mounts, motors, signal, ESCs, and the batteries) worked perfectly. In the appendix I have
chronologically shown my order of process with the build. Starting with the board of my choice, to
the decision of the motors and gearing, to the design of the motor mount, and to the ESC choice is
all shown. Conducted various tests with the material of the mounts.

Board
The budget for this project was set to $1000. I decided on the European Trampa
mountainboard which is $461, expensive but the quality is amazing! If I was new to the sport I
would pick a $100 ebay board with mountain board trucks.

Mechanical Components
The drivetrain for this build will be a belt setup. I am planning on going to a spur gear setup
in the coming months once I have read more about them. Using some online calculators for the
pulleys, belts, and the center distance, I was able to make my motor mount. I will be using the same
190kv motor but with less power from my previous setup (6374 190kv) and due to $40 difference in
the motors. This 6355 190kv will work fine with mountainboards though.

I had made 2 versions of the motor mount and 1 version of the pulleys.
V1 were the 3D printed pulleys (work really well) and 3D printed motor mount so I
can test them before machining it out of aluminum.
V2 mount was a big change. The rectangle that has to be matched to the hangar has
to be flipped to mount the motor mount on the other side of the hangar. It was
heavily inspired from TorqueBoards V4 motor mount which was designed for a
36T/16T setup. I increased the CTC (center to center) length to work with my
72T/14T setup. I like this setup so now all I need to do is flip the clamp.

The next plan was to make an enclosure for the VESC.

V1 of the enclosure was made out of PLA 3D material. I messed up my height of the
enclosure since I did not think the wires of the VESCs would be that bulky. That
enclosure has been put aside.
V2: For the next version I quickly put together a enclosure since I wanted to test the
progress of the build meaning if the VESC configuration, motors, and motor mounts
were all working correctly. To make the enclosure I found a plastic 30 degree plate
taken from a display case. I joined them at the appropriate width and cut it the
length where the VESCs and motors would be covered. Worked fine but I wanted
something professional.

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 V3: I wanted to try the carbon fiber hand lay method so I bought a starter kit online.
I will be making a mold for it in the meantime I wait for its delivery.

Electrical Components
For batteries I am sticking with my current LiPos I have. They are all balanced and still
work great. Recommend them a lot (Zippy 5000mah 30C 3S) to anyone starting out. In the
upcoming months I will change the battery system to Lithium-Ion batteries. They will be much safer
to work with and will include a BMS to manage the charge/discharge so I do not need to take them
off the board any more.
For the primary ESC, I will be using the ESC I currently have which is the VESC 4.12 from
OllinBoardCo. The secondary ESC is the VESC 4.12 from TorqueBoards. Both are great quality
ESCs but are limited to 50A continuous current. To get the most out of my setup I would need at
least 120A. This ESC setup will do for now and I will set it at 45A for safety of the VESCs..

Final Build Photos* (Ongoing)

SolidWorks Final Assembly

Finished build (Placeholder)

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Appendix

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Item Price (w/
Description Part Company
# tax&ship)
1 Trampa Short Deck Board $461.58 Trampa

2 TB 6355 190kv Motor [2] $180.00 DIYElectricSkateboard

3 Small Pulley (14T) - [1] $5.00 3D Print Test
4 Small Pulley (14T) - [2] $12.34 Ebay
5 Large Pulley (72T) - [2] $28.00 3D Print
6 Belt (450mm, 15mm) $18.48 V-Belt
7 Battery Enclosure - DIYElectricSkateboard
8 Mtn. Bike Pump - Pro Bike Tool
9 Motor Mount V1 - [1] Mechanical $20.00 3D Print Test
10 Motor Mount V2 - [2] $0.00 Scrap/Milled
11 Motor Mount V3 - [2] $36.00 Machined
12 Motor Mount Enclosure - [2] $0.00 Design/Scrap
13 VESC Enclosure - [1] $0.00 Design/3D Print
14 VESC Enclosure - [2] $70.00 Carbon Fiber
Large Pulley Screws
15 (M4x80mm) $20.00 McMaster-Carr

16 VESC, Ollin - [1] $99.00 DIYElectricSkateboard

17 VESC, TB - [1] - OllinBoardCo.
18 5.5mm Bullet Connector $9.25 Castle Creations
19 12 Gauge Wires $0.00 Amazon
20 Mini Remote Controller $36.80 E-Sk8 Market
Electrical
Batteries (3s 5000mAH Lipos)
21 - [3] - Zippy
22 iMax B6 LiPo Charger - iMax
23 Parallel LiPo Connector $25.00 Ebay
Future: 18560 Cells (LG HG2,
24 Sam. 30Q)

Total $1,021.45

Figure 1: Invoice of parts

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Figure 2: Schematics of the Trampa board my build will be going off from. Taken from Trampas
website.

Figure 3: My SolidWorks assembly (V1). Just the setup.

Figure 4: SolidWorks assembly (V2). Added VESC and batteries with the enclosures. Designed a
VESC enclosure. Made a new design with the guard. Made a new design with the motor mount.

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Figure 5: SolidWorks assembly (V2): Changed the design of the mount and guard. For the mount I
went to the tried and tested TorqueBoards V4 motor mount and redrew it in SW. Changed the CTC
to modify for my pulleys. Made the guard simple so it would be easy to machine. More info. down
below in the figures.

Figure 6: Using this online skateboard calculator from Todd T - Super Blog, I was able to calculate a
reasonable estimate of speed that I would attain with my gearing and batteries. The one on the right
is my setup (9S battery) and the one on the left is the calculations for a 12S battery. I can upgrade to
12S anytime but I do not want/need the speed/power.

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 Figure 7: Using this drawing and the variables in the table above from BeltingOnline, I was able to
make my own 72T pulley to be 3D printed.

Figure 8: Also with the same method, I was able to make my own 14T pulley. I have 3D printed it
but will only use it for demonstration purposes due to the teeth being too weak for the pulley power
of the belt. For this reason I will be using aluminum pulleys.

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Figure 9: To find the correct belt setup, I used the Center to Center calculator from SDP/SI and that
gave me a belt length of 450mm. It also gives me a center distance for my motor mount of
107.42mm. In general, Pulley As teeth in mesh should be 6 or more to attain maximum torque
transfer but here I have 5. I plan on changing that by adding in a belt tensioner and later on I will go
to a 15T and 66T pulley

Figure 10: Rough sketch of the motor mount position on the hangar.

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 Figure 11: Here is a FEA of the V3 motor mount. This is the stress of when there is an
application of 1100N of force (or 250lbf). The yield strength for 6061 T6 Aluminum is
275MPa and here the max stress is near the hangar mounting point is 27.6MPa. Really good
which means I can cut the material down significantly and still retain a good yield strength.
Although real world testing will definitely change that numbers but this here is a start.

Figure 12: Here is the displacement. It will bend downwards from the right by 0.05mm. Not
much and this will definitely happen slowly over time but again this is with a 250lbf which
is extreme.

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Figure 13: Here is the strain and the FOS of the mount. The strain is very much minimal to
even be considered and the FOS is over-compensated.

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 Figure 14: Designs that were 3D printed for testing before machining aluminum.

Figure 15: 3D printed ABS at 100% at solid infill. The 72T pulleys will be used in the final
build but the V1 motor mount and 14T pulley are just for the initial setup.

Figure 16: VESC Enclosure that was 3D printed on PLA (Did not need the ABS strength.
Took 14 hours). [Did not use for long as I did not account for the huge 10AWG wires]

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Figure 17: Have received the board, motors, and VESC

Figure 18: The 3D printed motor mount on the hangar.

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Figure 19: V2 mount. Inspired from TBs motor mount that I had on my previous build, this
was a better solution since I have tried and tested it. Worked like a charm!

Figure 20: Material to manufacture the V2 mount. 16 x 3 x 0.5 6061 - T6 Aluminum.

Figure 21: CTC on the V2 mount. Ranging from 120 to 95mm. Allowing me to pick many
variations of pulleys if torque or speed becomes important to me and I want to change.

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 Figure 22: V2 mount getting ready to be CNCd.

Figure 23: Two V2 mounts and the clamp after CNC-ing. Fitted perfectly to the board and
motor!

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 Figure 24: Cutting and tapping the clamp

Figure 25: Completed the main parts of the drivetrain. Will model the safety and the covers
for them next.

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Figure 26: First test ride at the park. It was a success! Everything stayed attached and went
on and off trail (grass, dirt, sidewalks). Now to work on the guard and enclosure for the
VESCs!

Figure 27: Found this plastic shelf piece from a display case lying around. I remodeled it in
SolidWorks and cut it at the width and length I needed to cover the VESCs and motors. Put

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some holes and painted it. My next task will be to cut at the angle of the tail but I need a
dremel for that which I will buy soon.

Figure 28: Went for my 2nd ride. The motor mount held really well after going off-road
dozen times. My next few tasks will be; properly attach the flashlight, make a better logo,
cut the VESC enclosure to the shape of the tail, and attach guards to the motors.

Figure 29: I am now making a Carbon Fiber composite for the VESCs. The mold will be
made out of the wood I have lying around. The epoxy, carbon fiber, and hardener all came
from Gorilla Carbon Works. *Figure is from Gorilla Carbon Works product page

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 ELECTRICAL POSTS

Figure 1.1: Diagram of the electrical connection of the batteries, ESCs, and motors.

Figure 2.1: Changed the connectors of both VESCs to 5.5mm bullet connectors to match the
motors and batteries. And because I also like those connectors.

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Figure 3.1: VESC Settings. Playing around with the current settings. Will keep it in BLDC
mode for now and at 45A max for safety and practice.

Figure 4.1: I have ordered some red/black silicon wire to extend my wires so it can loop
onto the bindings. Will be soldering them with my RadioShack Solder Iron I bought last
year.

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