Altered/Exkate electric skateboards/longboards are not known for their turning radius (it's HUGE), their weight (the one we used was 48 pounds stock!), nor their performance (1, yes ONE, wheel drive). In fact, about the only thing they are known for is being one of the first companies to produce electric skateboards/longboards. So we decided to make it better. The further we went, the more we realized we could have started with a deck and built up; thus, I will endeavor to make this Instructable useful to both types of builders.
CIM motors have been without a cheap, easy, and compact gear-reduction drive-train since their beginning. Now the wait is over. Read on!
The team was part of MIT's Edgerton Center Summer 2010 Engineering and Design Class, a month-long class where high school students learn and apply real-world engineering skills to various projects.
Note: I'll apologize in advance for any bad quality photos.
Also Note: I am in no way affiliated with any of the companies mentioned in this Instructable.
Step 1: Parts and Tools
Option A: Rebuild an Exkate.
1) Proline 600 Exkate (It's not worth buying one for $600. Go to option B if you don't already have one)
2) Two CIM motors
3) Two of these planetary gearboxes .
4) Some ¼" aluminum plate. At least 12" x 12".
5) Some 2" Aluminum round. At least 2" in length.
6) Two timing belt gears. A good source for these is: http://www.sdp-si.com/
7) Two timing belts . (We used 400-5M)
8) Two ball bearings that have OD’s small enough to fit inside the timing belt gear hubs and have a 5/16" ID. McMaster has cheap ones.
9) Two MBS mountain-board trucks .
10) Four ¼" rubber shock absorption (soft) risers
11) Nine lithium polymer batteries. We used these wired in 3S3P for a total of 9S3P (~36V and 6600mAh). Read up on safety information before using LiPo's!!! They can explode if used improperly!
12) Nine electronic project boxes (used as battery boxes). Preferably plastic and as close to the size of your batteries as possible.
13) About 6 feet of 14+AWG wire.
14) PTC fuses~1Amp. At least 24
15) Deans connectors or other low resistance battery connector. 1 pair
16) Three of these charger s or equivalent. (why you need three will become clear)
17) Three of these power supplies or equivalent.
18) Low voltage detectors or equivalent.
19) electrical tape/ assorted heat shrink tubing
20) Blue RTV silicon sealant or equivalent.
21) LED strips. We used two 12V 16" Red strips and one 12V 8" white strip.
22) Lots of various machine screws.
Optional: 3 balloons (for waterproofing LVD's), some extra hard bushings (rider's preference, but due to the extra long trucks, harder seems to be better), a small switch for the LED circuit
Option B: Build from ground up.
All of Option A minus the Exkate and plus the following:
1) A deck
2) An Altered electronics module .
3) Exkate Wheels: Two regular (http://www.alteredexkate.com/servlet/Detail?no=104 ) and two with drive gears (http://www.alteredexkate.com/servlet/Detail?no=103 )
Dremel with cut off, sanding, grinding bits
Hot glue gun
Hex keys, screw drivers, wrenches etc.
Tap and die set
Optional: Metal Lathe (very helpful), Cold saw