Hello everyone
This is a story about building a board with hub motors, a deck with brackets and Surfrodz TKP trucks, the enclosure is to be printed on a 3D printer.
It’s not a super performance board, it won’t be super fast with long range.
Deck is large and flexible so the ride is supposed to be comfortable… it is such a mini cruiser
Building this board is first and foremost a fun design 
is the only reason why I quit my corporate job and decided to earn money by creating my own parts for DIY enthusiasts.
I wanted to do this project a long time ago… it’s an amalgamation of many of my previous projects and a return to my roots because the ESC and battery enclosure will be printed on a 3D printer, and the printed enclosures were installed in my first 3 boards from 2014, 2015 and 2016 when I started the esk8 adventure
I designed the TKP hangers in 2019, the brackets are also an older design because it’s the 1st generation from 2019, which is still selling today
The first concept of my hub motor board was based on the Backfire G2T kit but I wanted a bit more power and larger wheel diameter so I went with Meepo motors with 105mm wheels, I don’t know who makes them but WOWGO uses the same motors in their boards.
I decided to use complete electronics from Meepo
I bought a Meepo Shuffle v4 and took it apart
The enclosure is designed to fit the esc and meepo switch, unfortunately the ESC is very unusual because it has a large heat sink that I have to cut off, moreover it is not small, the switch is also a bit problematic to assemble…
A better solution would be to use a set of other small ESCs and a classic switch, such as Backfire, WOWGO or Meepo but from V3/ NLS PRO /MINI 2/MINI 2S but designing a case for Shuffle v4 is an additional challenge
The idea of enclosure is unusual
I want it to be possible to remove the batteries, i.e. assembly without welding the batteries.
first enclosure contains 2 cassettes of 6 batteries each, a total of 12. Unfortunately, the ESC meepo accepts only 10S so I will use 10 batteries.
The goals of such an enclosure are 2:
-
I wants to encourage people to build their own boards… in the era of Chinese cheap boards building your own board in the garage for many people does not make sense… I don’t understand them because for me it’s great fun
but I don’t have to understand everyone 
, and seriously, screwing together a board many people will grasp, but building a battery pack is quite a challenge for many people. -
Such a board theoretically can be transported by airplane, so you can take it on vacation, batteries can be carried in hand luggage.
After the design of the enclosure is completed, it will be made available for self-printing
Such a solution is problematic because there is a risk of burning out the batterys contacts, but I like to experiment so I take the challenge 
The enclosure on the renders is the first enclosure with ESC, switch, charging port and 1 pack of batteries (12S1P or 10S1P). The batteries used are 21700
All parts except the enclosure are ready, the enclosure design is not finished, it’s a preliminary concept so many more hours of work and many printed prototypes ahead of me
A 1P battery is definitely not enough for me, so I will also design an additional smaller enclosure for an additional 10S1P pack (but with 12 chambers for 12S1P).
The packs will be interconnectable. the battery pack will be expandable to 12S4P.
The only thing that worries me is the BMS, for 1P BMS is not necessary (of course if new batteries are used), but for 4 packs without welding BMS would be a good option… this is a topic to think about
Parts list:
Deck - IDEA
Brackets - IDEA, type 1
TKP Hangers - IDEA
Base plates and bushing set - Surf-Rodz TKP HEX
Hub Motors - Meepo Shuffle v4
ESC, remote control - Meepo Shuffle v4
Battery - 10S1P and later 10S2P
I wrote about hangers in Vendor Corner but will repeat because it may be relevant
The biggest drawback of the Surf-rodz TKP trucks is the two-piece hanger, a cool idea, but dangerous because the thin M6 screws break.
I used M8 bolts for assembly, the cross-sectional area of an M8 bolt is almost 2 times that of an M6 bolt so the strength is much higher
Of course you have to ream the holes in the bushing set from 6 to 8mm but it’s easy to do
The front hanger is 260mm wide, this is the width without axles, it uses 10mm diameter axles.
The rear hanger is 180mm wide, after mounting the motors, the outer width of the front and rear wheels is very similar
This is not a commercial project, I made these hangers because I wanted to, of course if someone wants to build a similar board, I can make a few more sets
I also designed rear hangers for classic belt drives if you don’t like hub motors.
I plan to make clamp rings with 3 holes so that I can use Chinese gear drives for DKP trucks but that’s a topic for Vendor Corner
I didn’t like the Meepo hub motor covers so I made my own
