I started with this smooth acoustic ride:
Project Requirements (SOR)
| ITEM | DETAILS |
|---|---|
| Range: | 24-32 km (15-20 mi) |
| System Weight: | 9 kg (20 lb) target |
| Max Load: | 100 kg (220 lbs) |
| Top Speed: | 32 km/h (20 mph) |
| Acceleration: | Great ? |
| Braking: | Regen braking |
| Drive: | Dual motor, RWD |
| Control: | Hand-held controller w/ battery level display |
| Ground Clearance: | 6" wheels min |
| Terrain: | Streets, railroad tracks, potholes, grass |
| Slides: | Yes |
| Deck Flex: | Medium flex (bamboo, maple, fiberglass ) |
| Ride Quality: | Able to handle terrible urban roads |
| Ruggedness: | Designed for IP54. Rock guards over sensitive / moving parts. |
| Build Quality: | Fully functional for 2+ years, assuming regular maintenance & no major accident |
| Safety: | On/Off switch, protected. Headlight LEDs. Brake light LEDs. Able to pass for non-electric longboard, at a distance. Can be pushed |
| Ergonomics: | Hand-held pocket sized controller. Board carrying strap/handle |
| Aesthetics | Custom grip tape or skin |
| Budget ($) | 1200-1500 |
Parts List (BOM)
This build is not intended to push boundaries. This build was designed to utilize community-trusted parts and vendors to build a capable, reliable, and fun electric longboard. The entire project was started with a few goals in mind - not only to create a fun, custom esk8, but also to enjoy the build process, and improve my electrical knowledge in the process.
| PART | BRAND | MODEL | DETAILS | PRICE | SHIPPING+TAX | LINK | ORDER DATE | STATUS |
|---|---|---|---|---|---|---|---|---|
| DECK | Landyatchz | Drop Carve 38 Fox | deck only, 37.9" L, 9.7" W, 28" WB, 7 ply maple | $119.99 | $0.00 | https://landyachtz.com/product/drop-carve-38-fox/ | 1/2/2021 | Arrived |
| DECK BRACES | Dickyho | Deck Protectors | Heavy Duty Stainless Steel Skateboard Deck Protectors washers Set of 2 | $4.00 | $4.00 | Creative Heavy Duty Stainless Steel Skateboard Deck Protectors washers Set of 2 | eBay | 1/23/2021 | Arrived |
| TRUCKS | Boardnamics | BN220 Precision Trucks | Hangers, 50/40 baseplates, Riptide Sports 93a KranK barrel bushings and 96A pivot cups. | $129.99 | $0.00 | https://boardnamics.com/product/bn220-precision-trucks/ | 1/12/2021 | Arrived |
| TRUCK HARDWARE | Loaded | Drop Through Strips | shock absorbers, w/ washers | $3.95 | $0.00 | https://www.muirskate.com/longboard/risers/3499/0-13-khiro-drop-through-strips-shock-absorbing-risers | 1/18/2021 | Arrived |
| TRUCK HARDWARE | Bolt Depot | Axle Nuts | qty 4 5/16"-24 steel nylock nuts | $6.40 | $5.89 | https://www.boltdepot.com | 1/18/2021 | Arrived |
| TRUCK HARDWARE | Loaded | Button Head Flanged Hardware | qty 8x flanged button head hex 10-32 x 1.25" screws, qty 8x 10-32 locknuts | $6.95 | $0.00 | https://www.muirskate.com/longboard/products/71945/loaded-flanged-head-hardware | 1/22/2021 | Arrived |
| TRUCK HARDWARE | Dime Bag Hardware | Speed Kit | bearing spacers and speed rings | $4.50 | $0.37 | https://www.amazon.com/gp/product/B004QGAJ4G/ref=crt_ewc_title_srh_1?ie=UTF8&psc=1&smid=A3CDEUCT9UACPY | 1/18/2021 | Arrived |
| TRUCK HARDWARE | Riptide Sports | Small washers | 3/8" x 7/8" stainless flat washers | $1.50 | $3.35 | Small Flat Washers | RipTide Sports | 1/30/2021 | Arrived |
| DRIVE | Boardnamics | Dual M1 Drive | kegel wheel adapter. 64T wheel / 23T motor (straight gears) | $160.00 | $0.00 | Dual M1 Drive | | 1/31/2021 | Arrived |
| WHEELS | Torqueboards | 72a 110mm wheels | set of 4, kegel core | $90.00 | $15.00 | 110MM TORQUE Wheels (TB110) – DIY Electric Skateboard | 1/13/2021 | Arrived |
| WHEEL BEARINGS | Bones | Reds Bearings | 8mm ID, 22mm OD, 7mm W | |||||
| (8 pack W/Spacers and Washers) | $17.95 | $1.48 | https://www.amazon.com/gp/product/B0798WGCB1/ref=ox_sc_act_title_1?smid=A16ZC15ZGEH7W1&psc=1 | 2/9/2021 | Arrived | |||
| MOTORS | Flipsky | 6374 Brushless DC Outrunner Motors, 190kV | Battle hardened, balanced, sensored, qty 2, 3500W, 85A max, 8Nm msx torque, 14 pole, 12AWG phase wires, JST-PH connector for hall sensor wires, M4 mounting screws, 8mm shaft, with keyway & key | $162.00 | $34.50 | Flipsky BLDC Belt Motor Battle Hardened 6374 140KV 190KV 3500W for Ele – FLIPSKY | 1/17/2021 | Arrived |
| ESC | BKB | Xenith VESC dual motor | 2x MT60 Motor Connectors, 1x XT60-M 12AWG battery connector, single MCU architecture, 80A continuous motor current | $195.00 | $0.00 | BKB Xenith - VESC Based Motor Controller (High Power) – Build Kit Boards | 1/9/2021 | Arrived |
| REMOTE | Flipsky | VX2 Pro | UART | $63.75 | $13.50 | Screen Remote VX2 Pro for Electric skateboard | Flipsky VESC Remote with telemetry data – FLIPSKY | 1/3/2021 | Arrived |
| BATTERY | esk8life / thisguyhere | 10s4p P42A | w/ SMART BMS, XT90S female connector to VESC, 5.5x2.1 barrel plug for charging, Pack: 410x150x29 (16.9 x 5.9 x 1.14), BMS: 108x65x10, Inline fuse holder, glass 5x20mm fuses | $388.00 | $47.00 | https://esk8life.com/batt/index.html | 1/9/2021 | Arrived |
| BATTERY+VESC MOUNTING | 3M | 3M Dual lock heavy-duty 250/250 | 3M Dual Lock Reclosable Fastener SJ3560 250 Clear, 1 in x 6 Ft | $14.50 | $1.20 | https://www.amazon.com/3M-Reclosable-Fastener-SJ3560-Clear/dp/B00JHKTDMA/ref=sr_1_4?dchild=1&keywords=3m+dual+lock+250&qid=1611816860&sr=8-4 | 1/29/2021 | Arrived |
| BATTERY CUSHION | Aliexpress | 2mm x 20mm EVA sponge foam, adhesive back | to fill gaps and cushion everything inside enclosure | $1.65 | $3.14 | Strong adhesion EVA black sponge foam rubber tape anti collision seal strip 1, 2, 3mm thick|Tape| - AliExpress | 1/28/2021 | Arrived |
| CHARGER | YZPOWER | DC 10S 42V 4A 36V Lithium Ion Battery Charger | US Plug, 5.5x2.1 barrel connector (4.2 hrs charging est) | $23.32 | $0.00 | YZPOWER 42V 4A Lithium Li ion Battery Charger For 36V 4AH 5AH 8AH 10AH 20AH Lipo Bike Power Tool Scooter Battery Pack|battery charger|li-ion battery chargercharger for - AliExpress | 1/11/2021 | Arrived |
| ENCLOSURE | eBoosted / eboards | Evolve Bamboo GT | 630 x 230 x 33 | $125.00 | $45.00 | https://www.eboardsperu.com/product/evolve-bamboo-gt-enclosure/ | 1/19/2021 | Arrived |
| ENCLOSURE HARDWARE | SS M4/M5 inserts, GLUE them in | M4 button heads screws + steel finish washers + rubber washers + blue loctite 242, 8mm long insert? (measure deck thickness) | $5.21 | $0.00 | 20Pcs M4 Threaded Inserts Stainless Steel SUS303 Helical Insert Self Tapping Slotted Screw Thread Repair Insert|Threaded Insert| - AliExpress, 10pcs /bag, Colors Aluminum M4 Flat head Screw Washer Countersunk Head Washers Fender Washer|Washers| - AliExpress | Arrived | ||
| ENCLOSURE GASKET | Dicor | Butyl tape | Dicor BT-1834-1 1/8" x 3/4" x 30’ Butyl Seal Tape | $13.56 | $0.00 | https://www.amazon.com/XFasten-8-Inch-30-Foot-Sealing-Patching/dp/B06WLQ3WLS/ref=sr_1_5?dchild=1&keywords=butyl+tape+black&qid=1611819741&sr=8-5#customerReviews | 1/29/2021 | Arrived |
| ELECTRONICS SEAL | GE | Neutral core silicone II+ sealant | GE Silicone 2+ / Advanced | $3.77 | $0.00 | https://smile.amazon.com/Clear-Electronic-Grade-Silicone-Squeeze/dp/B0063U2RT8/ref=sr_1_2?dchild=1&keywords=neutral+cure+silicone&qid=1611125630&sr=8-2 | 2/12/2021 | Arrived |
| HEAT SHRINK | n/a | 220mm flat width, 0.15mm thick, PVC, Blue | DIY Battery Pack PVC Heat Shrink Wrap Tube Length 3M Width 220±5MM for Big Battery Pack Power | $15.36 | $0.00 | Amazon.com | 2/12/2021 | Arrived |
| HEAT SHRINK | n/a | 50mm dia Polyolefin, Clear | Heat Shrink Tubing, 2:1 Dia 2" Sleeving Wrap Cable Wire Electric Insulation Heat Shrinkable Tube Transparent 16Ft (Dia 50mm) | $13.99 | $0.00 | Amazon.com | 2/14/2021 | Arrived |
| CONNECTORS | Amass | XT90S | Parts List:, - XT90 Male - replace connector on VESC, - XT90 Male w/ 10/12 AWG pigtail - 3-way Loop #1 - connection to battery, - XT90S Female w/ 10/12 AWG pigtail - 3-way Loop #2 - connection to VESC, - XT90 Male connector - 3-way Loop #3 - bulkhead mount to enclosure for Loop Key, - dust/water cover - XT90 Male, rubber/TPU, attached | $12.96 | $0.00 | https://www.amazon.com/gp/product/B074PTHZ3M/ref=ppx_od_dt_b_asin_title_s00?ie=UTF8&psc=1 | 1/11/2021 | Arrived |
| CONNECTORS | Amass | XT30U | 10 pair | $8.99 | $0.00 | 2/14/2021 | Arrived | |
| CONNECTORS | Amass | MR60 | 10 pair | $15.99 | $1.32 | Amazon.com | 02/10/2021 | Arrived |
| TAPE | n/a | Kapton Tape | 1 roll, 13mm x 33m | $5.99 | $0.00 | Amazon.com | 02/10/2021 | Arrived |
| WIRING SLEEVE | n/a | 1/4 braided split sleeve | $0.00 | $0.00 | - | - | Had on hand | |
| ANTISPARK | DIY | XT90S Loop Key | bulkhead mount XT90 male, 3d printed handle w/ xt90s female, 3-way 12awg wire routing, Parts List:, - XT90S Female connector, - 10/12 AWG wire, - 3D printed handle, - 3D printed bulkhead/panel mount plate, - Potting compound / epoxy / JB weld, - Velcro to stick to controller when not in use, | |||||
| Mount to enclosure, to board, to trucks, or elsewhere | $0.00 | $0.00 | How to make a XT90 Loop key | Made | ||||
| CHARGE PORT FUSE | n/a | Mini Blade Fuse Holder, In-Line | 16AWG, 10A fuse | $7.99 | $0.00 | Amazon.com | 2/12/2021 | Arrived |
| DRIVE GREASE | Lucas Oil | 10005 Red’n’Tacky Grease | 14 oz tube | $4.99 | $0.41 | Amazon.com | - | Arrived |
| DRIVE LOCTITE | Loctite | 648 Green Retaining Compound | Low viscosity, high strength, high temp, press/close fit cylindrical parts | $19.00 | $1.57 | Amazon.com | 2/8/2021 | Arrived |
| AXLE LOCTITE | Loctite | 290 Green Wicking Threadlocker | $15.92 | $0.00 | Amazon.com | Arrived | ||
| FASTENER LOCTITE | Loctite | 243 Blue Medium Strength Threadlocker | $5.99 | $0.00 | Amazon.com | Arrived | ||
| LIGHT CONTROLLER | Arduino | Nano | From VESC → microcontroller → battery level, remote control commands (brake, accelerate), Microcontroller: ESP32, ESP8266, arduino nano, Teensy, etc, Need ambient light sensor (headlights vs drl), Need IMU for turning (brighter on turn side) | Let there be ESK8 lights - #274 by skelstar | ||||
| LIGHTS - REAR | LED strips | APA102 strip w/ SMD5050 | IP67 waterproof strip ($11.37), 2x short strips wrapping around each gear drive case - (only need red?) - brake lights | APA102 Smart LED Strip Pixels Light waterproof 5m 1m 30/60/144 LEDs/m Pixel DATA and CLOCK Seperately DC5V Strip Lights|seperate eggs|seperator filterseperation pad - AliExpress | ||||
| LIGHTS - FRONT | Flashlight / headlamp | Flashlight, remotely powered, multiple brightness settings? | ||||||
| LIGHTS POWER | Buck converter | DC-DC step down buck converter ($2) | DC DC Buck Converter KIT Adjustable Power Supply DC DC Step Down Adapter 3A LM2596HVS LM2596HV Step Down Power 4.5 55V To 3 40V|dc buck converter|buck converterdc dc - AliExpress | |||||
| SKATE TOOL | Zeato | All-in-One | Skate Tools Multi-Function Portable Skateboard Y Tool Accessory with Y-Type Allen Key and L-Type Phillips Head Wrench Screwdriver - Green | $10.98 | $0.00 | Amazon.com | ||
| OPTIONAL: | ||||||||
| WHEEL LIGHTS | motion activated, wireless | |||||||
| GEARS #2 | Boardnamics | Helical gear set (pinion & drive) | 60/22 (helical) - $60 | TBD April | ||||
| POCKET FUEL GAUGE | DIY | 42v LED display, waterproof | voltage / remaining battery display, in 3D printed case, power pass thru, Pocketable Fuel Gauges: pictures and howto [serious] - #4 by b2640https://www.thingiverse.com/thing:4231643 | $19.89 | $1.64 | https://smile.amazon.com/gp/product/B07KS1G585/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1https://smile.amazon.com/gp/product/B08SJM2G52/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8&psc=1 | 2/15/2020 | Arrived |
| SAFETY - FIRE BLANKET | Tonkyo | Fiberglass Fire Blanket | 47.2 x 70.9 in | $19.99 | $0.00 | Amazon.com | 2/10/2020 | Arrived |
| SAFETY - LIION FIRE EXTINGUISHER | ||||||||
| SAFETY - HELMET | Dainese | Use existing helmet | $0.00 | $0.00 | - | - | Have | |
| BRAKE LIGHT | Nkomax | Smart Bike Tail Light | Ultra Bright, Bike Light Rechargeable Auto On/Off, IPX6 Waterproof LED Bicycle Lights, High Intensity Rear Accessories Fits Any Road Bikes ($24), Power via main pack w/ DC-DC buck converter | https://www.amazon.com/dp/B07DF8RTM4/ref=cm_sw_r_cp_api_gE8pBbPBV2KW8 | ||||
| BAG + DECK | Bustin | Mystery Box | ($169) | https://bustinboards.com/collections/skateboard-and-longboard-mystery-boxes/products/one-bag-box | ||||
| SUBTOTAL | $1,719.02 | $179.37 | ||||||
| TOTAL | $1,898.39 |
Begin The Build
All the photos.
Finished up the electrical wiring & soldering:
- Battery pack gets XT90S’s
- Xenith has XT60s
- Charge port gets XT30s
- Wired the loopkey loop
- Replaced the battery’s glass fuse with a mini blade fuse holder & installed 10A fuse
- VX2 bluetooth pcb got conformal coated
- VX2 and BMS bluetooth pcbs got heat-shrinked and silicone sealed (GE 2 Advanced 100% neutral cure).
- I had to resolder some of the BMS wires to lay along the long edge. Soldered a length of 12AWG to the BMS discharge port for future lights / arduino power (covered in cheap yellow heat shrink)
- Heat-shrunk the entire BMS
Xiaoxiang android app for the SmartBMS. I adjusted the parameters before the first charge - all to be more conservative. But if anyone wants to review these, I would greatly appreciate a second or third pair of eyes.
Next Steps
Time to build the @mmaner pocket fuel/voltmeter gauge. I’ll design and 3D print a case. I think I can build a slightly more compact version, and then waterproof it.
The big unknown is how to go about shortening the enclosure. The FrostKing 3/4 in. x 7/16 in. neoprene foam tape for the enclosure gasket just arrived. Will check to see if that’ll be enough to mount everything. Right now the wires on top of the battery pack rub first.
I’ve been thinking about dremeling off a ~3" length (will measure) out of the left-center area of the enclosure, so the battery is fully protected by a single piece. Then weld/join the two remaining pieces together with more epoxy + fiberglass mat.
