My E-Scooter Upgrade Project

Lightweight / Folding / Portable EVs - seats optional

Re: My E-Scooter Upgrade Project

Postby E-ScooterDude » Fri Mar 17, 2017 10:51 pm

Thanks IanHill, I'll check it out.
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Re: My E-Scooter Upgrade Project

Postby ElectricGod » Mon Mar 20, 2017 8:31 pm

E-ScooterDude wrote:I was planning on making my own brackets from .25" aluminum, that way I can get exactly what I want. So, do you like this type or the "Huating" type of caliper?


OK....yes cool...so not a problem mating it to fit those elongated slots. Those are very similar to my calipers. They work well considering how inexpensive they are. I should have gotten aluminum back when I mounted my brakes and made my own brackets. When you bleed the brakes, make sure before hand that the rotor is centered in the pads. I forget which brake it was...front or back, but one of mine was off center. It makes the brake caliper feel really spongy. It's kind of like the line has air in it. This morning, I crossed a railroad track and a piece of bailing wire got caught in my front rotor between one of the pads. It did the same thing. All of a sudden the front brakes were totally soft. As soon as I removed the piece of wire, the brakes were back.
E-Bike XB-502 (Moped) conversion project
viewtopic.php?f=10&t=83302&p=1222730#p1222730

Currie kick scooter conversion project
viewtopic.php?f=35&t=83830&p=1227407#p1227407

My kick scooter project
viewtopic.php?f=35&t=75177
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Re: My E-Scooter Upgrade Project

Postby ElectricGod » Sat Mar 25, 2017 7:23 pm

I don't know if you are going to use bike hydraulic levers or not, but I found these on ebay for $30 for both left and right. I bought them on Tuesday and they arrived today. They are missing the brake switch, but they cost like $2 each so no big deal. They are the correct size for bikes or my scooters.

http://www.ebay.com/itm/151373413004?_t ... EBIDX%3AIT

Here's the brake switches.

http://www.ebay.com/itm/4-Micro-Brake-S ... XQC-tTGiav

They are smooth and they come in sets. Hunting around for a matching set used to be a royal pain. Now a few companies are pairing them together for us and still selling them at reasonable prices. I think the brakes on my blue scooter cost me something like $24 each and I had to hunt around to find a left and right matching pair. Also these ones have a site window on them so you can see if you are low on fluid without opening them up. My old ones don't have that. They use 8mm banjo bolts.

Image
Image

This is the brake switches on my old brake levers. Get some of these for the new levers.

Image
Last edited by ElectricGod on Sat Mar 25, 2017 7:25 pm, edited 1 time in total. View post history.
E-Bike XB-502 (Moped) conversion project
viewtopic.php?f=10&t=83302&p=1222730#p1222730

Currie kick scooter conversion project
viewtopic.php?f=35&t=83830&p=1227407#p1227407

My kick scooter project
viewtopic.php?f=35&t=75177
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Re: My E-Scooter Upgrade Project

Postby E-ScooterDude » Sat Mar 25, 2017 11:01 pm

Thanks EG,

I totally scrapped the idea of using bike brakes and have focused on the scooter brakes. I got LH and RH (the RH has come in already) master cylinders that look exactly like the one's in the pictures. The parts I have come with the switch, stock long lever, and 8mm holes for the mirrors. I've also got the F and R calipers and some shorty adjustable levers coming too. I'll have to see about some custom lines. The .25" aluminum 6061 plate is on it's way. I know the brackets aren't right for my bike so I'm custom fabricating them. We'll see how this works out as far as the bolt-up goes.
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Re: My E-Scooter Upgrade Project

Postby ElectricGod » Sun Mar 26, 2017 7:10 pm

E-ScooterDude wrote:Thanks EG,

I totally scrapped the idea of using bike brakes and have focused on the scooter brakes. I got LH and RH (the RH has come in already) master cylinders that look exactly like the one's in the pictures. The parts I have come with the switch, stock long lever, and 8mm holes for the mirrors. I've also got the F and R calipers and some shorty adjustable levers coming too. I'll have to see about some custom lines. The .25" aluminum 6061 plate is on it's way. I know the brackets aren't right for my bike so I'm custom fabricating them. We'll see how this works out as far as the bolt-up goes.


I wish I had reused the existing elongated holes for my brakes, but made the existing brackets work instead which meant new holes. Now that I have 6061, I could do it right no problem, but it hardly matters now.
E-Bike XB-502 (Moped) conversion project
viewtopic.php?f=10&t=83302&p=1222730#p1222730

Currie kick scooter conversion project
viewtopic.php?f=35&t=83830&p=1227407#p1227407

My kick scooter project
viewtopic.php?f=35&t=75177
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Re: My E-Scooter Upgrade Project

Postby E-ScooterDude » Sat May 06, 2017 10:32 pm

I’ve done a lot of riding in the last month and I’m not too far from my first 1000 miles. All of the parts for the hydraulic brakes showed up a few weeks ago but I’ve been putting it off and riding instead. Well, I decided to at least install one of the calipers and I’m very happy with the result. I was concerned that these two piston calipers were going to be a bit too powerful and that would make the brakes too sensitive. I’m happy to report that’s not the case at all and the brakes, while powerful, are very controllable and linear.
Back brake Caliper.jpg

Master Cylinder.jpg

I also decided to go with a bigger sprocket. I asked LightningRods to make me a custom 64T sprocket with the intention of trading speed for torque. That’s exactly what I got and I lost about 7 MPH but gained some impressive hill climbing capability. The 50T seemed capable of anything but I found myself off-road way more than I expected. I’m on mountain bike trails, and even foot paths a lot and the 50T was not as ready for these as I would have liked. The motor puts out amazing torque but I found myself going slow up steep soft slopes. The 64T really pulls and now I can do what most mountain bikes can do. If it gets too rocky I have to walk it or turn back, but that doesn’t happen that often. I’ve been on some amazing trails and I have surprised a number of folks who see me out where a bike like this normally can’t go.
Sprocket.jpg

I built what I think is a really good chain tensioner, all for about $5. I noticed that the chain was either too tight or too sloppy. I knew that I would need to add a chain tensioner at some point but the off-the-shelf parts weren’t what I wanted. There is a natural pivot on the back side of the shock mount so I fabricated the arm and put on a urethane roller that works great. Getting the right spring for getting the tension just right was probably the hardest part.
Tensioner.jpg

I need to put the front caliper on and install the brake light and turn indicators. I have most of the parts for that but I’m not in too big of a hurry about that either. I’ll probably get that done this month.
A few last things: this bike really gets attention wherever I go. It seems everyone wants to know about its capabilities: cost, range, speed, etc. I know it’s unique but the interest has far surpassed what I was expecting. It really has turned out to be a most impressive little machine and has opened a lot of the area up to me for exploring. When there is a bike lane I take it. When there is only a sidewalk I ride that, but at reduced speed. When there are foot trails or bike paths, I take them too. When there is only road then I join traffic and can keep up for as long as I like, usually looking for another bike lane or sidewalk because I’m pretty happy doing around 15-20 MPH most times. My max speed so far is 53.6 MPH on level ground and my max range so far is 38.8 miles keeping my speed reasonable. If I’m rocketing around on the roads my range naturally is less, but only by about 10-20%.
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Re: My E-Scooter Upgrade Project

Postby LightningRods » Sat May 06, 2017 11:18 pm

I'm glad the sprocket worked out for you. The bike is looking great!
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Re: My E-Scooter Upgrade Project

Postby E-ScooterDude » Sat May 06, 2017 11:24 pm

Thanks Michael, I appreciate your help.
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Re: My E-Scooter Upgrade Project

Postby E-ScooterDude » Fri May 12, 2017 5:02 pm

This part of the project is complete: I installed the front brake caliper and master cylinder.
Front brake caliper.jpg


I also completed the 12V system, so now I have my brake light back. I just need to install the turn indicators.
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