Boxer FS-2 Electric Conversion

pattyballs · May 20, 2019

Hi All,
I am not new to the EV world, but have taken on a new project i would appreciate some input on. I have acquired a collection of Santa Cruz Scooter Works Boxer gas scooter parts/frames and would like to convert one of the full suspension models into electric. They have an interesting motor mount that i am pretty sure i can get an electric motor to bolt right up to. But i need some help...

I have rear sprockets in varying sizes that are sized for #25 chain so i would like a motor at uses the same sprockets. I would also like something as easy as possible to setup as i am not very savy with electronics, i am not looking to take this on long rides, just short 10 minute or so cruises around my property and nearby dirt trails. I would like to use some sort of lipo battery(s). And i am thinking of keeping it simple and mounting everything under the stock deck and might 3d print some sort of cover.

With all that, i am about 230 lbs so i would need a motor capable of getting me going and getting up some hills (nothing too crazy). I have seen the generic motor kits on ebay and amazon with 1000+ watt motors kinda curious to get your guys thoughts on those.

Thanks.

pattyballs · May 21, 2019

I had a chance to trace the motor mount and take some measurements. The center hole has a 2" diameter and the mounting holes are 2-3/4" apart from center to center. And from the face of the motor i would need a shaft approximately 2 inches long to mount the sprocket. Now to try and find a motor that will mount up and "Somewhat" fit.

Ianhill · May 21, 2019

The 2 inch motor shaft will be the issue, most motors sit the sprocket around 1 inch from the face of the motor, what type of power output are you looking for do you have a controller battery and motor in mind ?

I like the front fork you have i would like to make one do you have a picture of the otherside, its different to all scooter forks ive seen before some have the suspension but its mounted different looks a nice find.

pattyballs · May 21, 2019

Hey! At the moment i am open to all suggestions for all of the components. They are great scooters, heavy duty and ride really nice with the suspension. The biggest issue with them is that they were produced in low numbers making parts damn near impossible to find. Thankfully i have enough parts to make 4 of them with some spare parts.

But, yes it appears that my hurdle is the length of the motor shaft. Hoping that you or someone here can help.

pattyballs · May 21, 2019

Pics of suspension fork.

Ianhill · May 21, 2019

Id fit a hub like this one from aliexpress.

Then theres no chain to maintain the motor bracket can be cut off and place a controller in its place or in a battery tray, check ground clearence whith suspension travel taken into account so you dont ground out on the tray if you build one up underneath.

Cheers for the pics.

pattyballs · May 21, 2019

Thats a neat idea, so you would mount that in the rear i assume and just run one? Any suggestion on a controller or batteries to pair with? I really like this option!

Ianhill · May 21, 2019

What type of price range and skill you got, you can either use a 60v built 18650 pack and charger for an ebike, build a custom 18650 pack yourself thats not for the faint hearted and needs a true enthusiast hobbiest to take on or last ootikn use rc lipo and run them in series to get 60v.

For a controller you can use a powervelocity ebike type controller easy to set up and use mostly plug and play or theres the vesc scene with custom controllers coming out in small production numbers all the time more hsrdbto come by and use but more functiinality and tuning for the end user.

If you lengthed the heighy of the front shock a little so use one a little longer it would buy you the height clearence to fit one on the front but the width/dropout on the frame needs to be 145mm wide to fit the hub i can check that figure for you but ill need a day to look at the one i got in my house im gonna run a single hub and make a light weight simple build at 48v myself with a vesc powering it at 3kw but a crazy build may have two of the hubs and two controllers running 72v maybe 5kw peak each for crazy speed only a very strong frame could handle and a trained maniac should ride.

pattyballs · May 21, 2019

0 skill, so i would not even think to try to build the battery myself. As far as budget, i would like to keep it as cost effective as possible but willing to pay for quality components that i can continue using. I would love to find that wheel/hub motor somewhere easier to buy that will get to me quicker too, they usually take a long time.

As far as batteries i would like something plug and play(ish). Maybe 2 seperate packs that can plug in series 1 cell thick x 1 cell wide and 10 inches long.

Ianhill · May 21, 2019

I ordered a wheel to the uk took 7 days to clear shipping then less than 14 days its at my door no hidden custom charges, the product is decent enough for its price theres no better wheel that offers as much power in such a small size.

Id get lipo pouches then something like a 12ah graphene cell from multistar or simular and use a rc charger to charge in a pair thats how i started out 2 8s packs that i would series to run then seperate and balance charge in two halfs with a rc 8s charger and use a cell monitor when using them so i would not over discharge them.

pattyballs · May 22, 2019

Wheel Motor:
https://www.aliexpress.com/item/32870227208.html?spm=2114.search0104.3.1.6c21566dyfbvqK&ws_ab_test=searchweb0_0%2Csearchweb201602_7_10065_10130_10068_10890_10547_319_10546_317_10548_10545_10696_453_10084_454_10083_10618_10307_537_536_10059_10884_10887_321_322_10103%2Csearchweb201603_52%2CppcSwitch_0&algo_expid=9db593ca-3021-4cf5-a644-6de548f0663e-0&algo_pvid=9db593ca-3021-4cf5-a644-6de548f0663e&transAbTest=ae803_3

Controller:
https://www.aliexpress.com/item/32825213820.html?spm=a2g0o.detail.1000023.4.472d64adCloHo1

Battery:
https://www.aliexpress.com/item/32845698347.html?spm=2114.search0204.3.248.7d5f7d50ZagJlB&ws_ab_test=searchweb0_0%2Csearchweb201602_7_10065_10130_10068_10890_10547_319_10546_317_10548_10545_10696_453_10084_454_10083_10618_10307_537_536_10059_10884_10887_321_322_10103%2Csearchweb201603_52%2CppcSwitch_0&algo_expid=fcf6b232-2b53-4924-bf0c-482be67474d3-36&algo_pvid=fcf6b232-2b53-4924-bf0c-482be67474d3&transAbTest=ae803_3

Do you think this setup would work together?

Ianhill · May 22, 2019

Needs a bit more power on the controller and battery side it would work but be quite weak power wise.

pattyballs · May 22, 2019

Controller:
https://www.aliexpress.com/item/32869959548.html?spm=a2g0o.detail.1000023.8.4d755538XI85KL

Battery:
https://www.aliexpress.com/item/33012911143.html?spm=2114.search0204.3.2.34707d50mEnJcI&ws_ab_test=searchweb0_0%2Csearchweb201602_7_10065_10130_10068_10890_10547_319_10546_317_10548_10545_10696_453_10084_454_10083_10618_10307_537_536_10059_10884_10887_321_322_10103%2Csearchweb201603_52%2CppcSwitch_0&algo_expid=4706471a-0b1d-4273-9fab-3019cd755623-0&algo_pvid=4706471a-0b1d-4273-9fab-3019cd755623&transAbTest=ae803_3

Would these be better? Sorry, i am a novice when it comes to all of these specs and such.

Ianhill · May 22, 2019

Much better, whats the plan use 2 batterys in series for 72v it will do about 50mph i would have thought.

You should be ok on the dropout width.

pattyballs · May 22, 2019

Im thinking just 1 battery to start. Should be quick enough, i would think...

Since you have used this wheel, what would you suggest to do about mounting it? I plan on using the stock axle holes and the frame is exactly 140mm wide. I am just not sure how i can get it in there, or if i should cut the bottom of the axle hole and slide it in, kind of how mountain bikes are.

Ianhill · May 22, 2019

36v should get you moving about with decent moment say 20 mph or so.

Id check out torque arms for hubs so you can see how they lock down, personaly id slot the hole like you said then the wheel will slide in then id have a torque arm either side that picks up on the axle oval with say 4mm plate and bolts down to the wheel enclosure.

Like this.

pattyballs · May 28, 2019

What are your thoughts on this kit? I was about to place the order on the other items we had been speaking about, but realize that it was an 11 inch wheel and i can only fit a 10 inch wheel. I did se this kit and it is all there and should be easy to asemble. I would probably pair it with the battery i linked prior or maybe something a little more powerful.

https://www.leafbike.com/products/diy-bike-conversion-kit/10-inch-electric-hub-motor-kit/10-inch-48v-800w-electric-scooter-kit-rear-wheel-1100.html

Ianhill · May 29, 2019

I avoided that type of hub as they are geared so don't tend to be as good as the direct drives, the 11 inch stands 1cm taller it fits a razor e300 frame with 10 inch tyres, take some time don't rush it get a good idea what you want.

pattyballs · Jun 3, 2019

Ok, motor has been purchased. I have been looking into controllers some more and found this one. It is a little more than the other one, but like the bluetooth programming and being able to use a phone for a speedo and control all of the settings. Any thoughts on it? It goes up to 72v, so should be compatable correct?

https://lunacycle.com/60-amp-36-72v-ebike-bluetooth-programmable-controller/

Ianhill · Jun 4, 2019

The first motor posted is purchased ? The line controller will be fine I use something simular on my ebike and found it does the job well adjustable settings and a basic regen function that is not variable but is adjustable in software so it can be strong or weak, should make a decent ride with the choice of voltage ranges it's ideal.

pattyballs · Jun 4, 2019

I ended up purchasing the hub motor that you suggested. The price went up by $45, but thankfully i spoke with the seller and they reduced back down. I am happy to hear that the controller will work, will be nice to have the option to control the power output should the wife want to give it a go or something. Now i am stuck on the battery and throttle. I have been eyeing the throttle that boosted boards has been flaunting on their new scooter.

I am also torn on the battery. Looking into having a custom battery built as i have very limited space. Though, i might end up going with 2-3 RC batteries. Would really appreciate some input on batteries if you have a moment.

Ianhill · Jun 5, 2019

I've got a basic thumb throttle on one ride and a domino throttle on the other the domino feels nice very smooth but the price is high.

For compact size lipo has good discharge power they sag little, got a 60amp load of say you would want a cell around 12ah and 10c something like a graphene cell from hobbyking I've got a 10ah version and they deliver 60amp without warming up so can be pushed hard no issues.

I'd say with that motor controller and battery setup the weak links will be taken care off the motor will handle anything the controller can dish out and the batterys will have more than enough power just keep good air flow to the controller case and your golden.

pattyballs · Jun 5, 2019

Ok, do you think that this battery would work well? Price is very affordable only concern is having to solder a connector to the controller.

pattyballs · Jun 5, 2019

Battery:
https://hobbyking.com/en_us/turnigy-high-capacity-battery-12000mah-6s-12c-drone-lipo-pack-xt90.html?countrycode=US&gclsrc=aw.ds&&gclid=CjwKCAjw0N3nBRBvEiwAHMwvNi5PMDTE2CMq6peAuNRivwb_f1pntXYzUVeDepBVfUgDM4XURwLc4hoCQ0IQAvD_BwE

Ianhill · Jun 5, 2019

Plenty of power in that battery but beware minimum cell count for that controller is 10s/36v upto 20s/72v so two of those packs would be needed and you would be running 44.4v nominal 50.4v full pack voltage, you would have quite decent performance put of that then easily match the original 2 stroke unit with alot more usable torque smooth power delivery.

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