Do you remember this frame design about a month ago?

Now all the ordered parts came in and it is time to electrify this frame!

The purpose of this ongoing project is to create an efficient, light, affordable, and very cool means of electric urban transportation.

This instructable concludes the first version of such a vehicle. There are more cool stuff on the way, so stay tuned:

The ongoing project: http://dosimplecarbon.com/the-project/

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And follow us on Instagram: https://www.instagram.com/dosimplecarbon/

And YouTube:

https://www.youtube.com/channel/UCQP8FRNYs3G2mc9If...

Let's begin!

Step 1: The Drive Train: Fitting Pulley to the Wheel

We are using belt drive, I've ordered this set.

First attaching the bigger pulley to the wheel.

Center the pulley with the wheel, you might want to reverse it for this.

Then use press drill to drill the appropriate holes.

With the provided hardware attach the pulley through the opposite plate with 6 bolts.

Test fit on the trucks.

The process is simple but kinda messy because of the mushy drilling through PU wheel.

Step 2: The Drive Train: Motor Mount and the Motor

This motor mount was not a good companion for my trucks.

I needed it to go further towards the center, but there is a reinforcing rib that stands in the way. My way to deal with this was to make a recess for the rib in the motor mount. I used a Dremel tool and a router attachment for this.

Once it was where it should, it was held in place by 3 M6 grub bolts, and to my surprise it holds very good.

The motor was a perfect fit for the mount. A small fix was needed for the shaft. The grub bolts from the pulley would slip on the shaft. I made a short flat surfaces on the motor shaft with Dremel. Simple and efficient solution.

Step 3: Making the Battery Harness and Fitting the ESC and the Receiver

After printing my original parts, I was in a kind of misfit with the battery enclosure...

It was redesigned and reprinted, and the batteries were a perfect fit with the spare room for the harness.

The harness connects the two batteries in series to create one 22.2V+ source for the motor.

I used 12 AWG silicon wire with XT60 connectors. Make sure you have enough slack in the wires to conveniently connect batteries when needed. Also make sure that the soldering angles are the correct ones by design. This wire is thick and it can be challenging to fit it in tight corners or turns.

Note that I forgot to account for the connecting hole between two battery chambers, so it was simply drilled.

Finally the female connector for the ESC (Electronic Speed Controller) was glued to the enclosure and there is no need to reopen the hatches to arm the motor.

Finally it was time to glue in the ESC to the enclosure. It was done with hot glue into a dedicated spot, it made a really good fit.

And the very final step was to glue in the receiver, this was done with hot glue as well. It was glued in a way as to not disturb the battery.

Step 4: Assemble the Vehicle

We have completed the separate parts, now it is time to put everything together.

The enclosure is attached by 12 bolts through an upper adapter. The nice thing here is that you can slide it along the tubes at anytime, and can adjust the exact location depending on the wire length that you have.

Do drilling or wood filling is required, as it is the case in wooden decks :)

When everything was assembled, I took it for a quick weighting. Slightly above 4.2kg!!

This is really great and makes it totally possible to get below 4kg and to carry it daily.