Introduction: Electric Scooter Pushed by Monkey

This instructable is about an electric scooter I built and later added a sock monkey at the back which appears to be pushing.  I built this scooter loosely based on a 1950's era Cushman scooter at roughly 2/3rds scale.  The scooter is powered by 3 12v 10amp lead acid batteries wired in a series to get 36 volts.
 

Step 1: Materials & Tools Required

The scooter required the following:

1 inch angle iron (approximately 18 feet)
a scap piece of 1/8th steel plate
36v DC motor (purchased from a surplus store)
36v DC controller (purchased from a surplus store)
two band brakes
two low speed wheels & tires (2-wheel "dolly" tires)
two handbrake levers and cables (from an old bicycle)
one throttle (compatible with the DC controller)
large chain gear for the rear wheel
drive chain
headlight & tail light components (auto store & hardware store)
scrap plywood for the body panels
two bearings I had laying around (for the front forks)
misc. nuts, bolts, switches, and wire

The sock monkey required the following:

2x2 lumber for the internal framework
various hardware store hinges for the moving parts
a couple of lawn mower wheels
scrap steel
a sock monkey infant costume (from a department store)
one small plastic bowl (stolen from my wife's kitchen cabinet)

Tools required:

metal cutting saw
electric welder
grinder
drill & various bits
wood cutting saw (for body panels)
soldering gun, solder, various electrical connectors
wrenches, screwdrivers, pliers, cutters, and bandaids....lot's of bandaids!

Step 2: Building the Frame

I didn't have any plans when I started this project, but I had seen a drawing from an old Popular Mechanic's article on the internet, and that's what I loosely based the frame design on.

I began by cutting pieces for the base frame (the rectangular part in the photo), clamping pieces together to determine a reasonable size, then cutting them to length and welding.

Next, I cut the pieces for the front forks and welded them together.  

The final bit of welding was to connect the base frame to the fork tube.  I made the fork tube from a short length of pipe, and shaved it down a bit on the inside so two bearings I had in my junk pile could be pressed in.  The forks attach to the fork tube with a long bolt.

The handlebars were made from a piece of electrical conduit, and bent to shape.  I attached them to the top of the forks with two u-shaped clamps.
 

Step 3: Wheels & Brakes

The drum for the band brake was bolted directly to the rim for both wheels, and a cable was run from the band to the handbrake controls.  I don't have a photo of the brake set-up for the rear wheel, but it is similar to the one on the front wheel. 

The rear wheel also has a sproket bolted to the rim, with spacers providing clearance between the sproket and the tire.  Again, I don't have a photo of this part.

I made spacers for both wheels to keep the wheels from sliding back and forth (you can see one of the spacers in the photo of the rear wheel).  All spacers were cut from scrap steel pipe.

Step 4: Mount the Running Gear

I mounted the 36v motor, using 1/8th steel plate for a mounting base, and carefully aligning the sproket on the rear wheel with the sproket on the motor.

In this photo I have temporarily mounted the controller and the batteries, and installed the throttle for my initial test run.  That's me sitting on a milk crate.  Not too comfortable at this point, but I was happy with its initial test run!

Step 5: Body Panels

For the main body panel, I basically made a slanted box with a shelf in the middle.  The bottom of the box is open to provide clearance for the motor, drive chain, and rear wheel.

The shelf in the middle houses the controller and the three 12v batteries.  This rear body section was made from some scap 1/2" plywood I had laying around.

The front panel (on the forks) was made from a piece of scap masonite.

I found an adjustable bicycle kickstand at WalMart, cut it down to fit the scooter, and bolted it to the frame.

The floor board was made from plywood and covered with stair tread for protection.

The seat was made from a piece of plywood as a base, and covered with high density foam and vinyl.

 

Step 6: Lights, Etc.

I built a 12v headlight using a landscape light bulb and a chrome plumbing part.  I am of the belief that virtually anything can be made from plumbing parts!

The tail light (not shown) is a trailer tail light from an auto store.

Since my plan was to ride this is some Christmas parades, I also added battery operated light strings around the forks and on each side of the back of the scooter.

To power all these lights I added another independent battery pack (black box at the back of the floor boards), with a toggle switch to turn them on/off.

I happend to find a small piece of aluminum sheet in my scrap pile, so I added a front fender.

I then made a shroud from kydex plastic to protect the end of the motor in case I ran into any rain falling.

Step 7: Adding the Sock Monkey


I didn't take a photo of the frame built for the sock monkey, but it is basically a fixed wooden frame with hinged legs.  Each leg attaches to an 8 inch wheel with a bolt that allows the foot to pivot as the wheel rotates, giving the impression that the little monkey is walking/running when the scooter is moving. 

The wheeled aparatus is connected to the scooter with a small trailer hitch.  The monkey's head is built around an inverted plastic bowl mounted on a spring, so it bobs a little as you travel along.

The video will give you an idea of how this all works together.  By the way, the sound you hear on the video is not from this little scooter -- there was a mowing crew nearby that drove their mowers over to see this little machine ride around the parking lot. 

Step 8: Having Fun!

My wife and I have had a lot of fun with this scooter.  It's always a hit wherever we take it!  My favorite use is in Christmas parades.  All I hear through the entire parade route is hilarious laughter as people point to the little sock monkey that appears to be pushing me along.

Comments

author
floydaroo made it!(author)2017-05-24

could you draw out a wiring diagram? I know that you did not have schematics. I have no welding experience and would like to know if I could make it out of pvc pipe? As you said, "I am of the belief that virtually anything can be made of plumbing parts".

author
goldenshuttle made it!(author)2015-09-06

Nice project. The brakes idea is quite new. thumbs up.

author
HADJISTYLLIS made it!(author)2013-06-29

great instructable.great work with the monkey.awsome i'm starting building this already

author
dobbo made it!(author)2011-11-29

It looks like an old Cushman scooter?

author
knife141 made it!(author)2011-11-29

I based it (from memory) on an old Cushman Highlander, only it is about 1/5 - 1/3 the size.

author
Xray_Man made it!(author)2011-10-17

There is very little detail about the motor and electronic drive in this Instructable. Could you provide more detail about their specifications (including manufacturer and model numbers)? Also, needed are details of how the motor and drive were mounted, what type of speed control did you use, and also need a schematic wiring diagram. I would like to build a scooter, but it would be very difficult withour more detail.

author
knife141 made it!(author)2011-10-23

Sorry I took so long to respond. I purchased the motor and controller from a surplus store, and the only info I had was that both were rated for 36 volts. Fortunately, the wires on the controller were all labeled -- that helped a lot. I used a throttle mounted speed control (the kind made for commercial electric scooters). Unfortunately I have no schematic -- I just sort of planned it as I went along.

author
WiredWebbo101 made it!(author)2011-05-05

Fantastic work, I wonder if I could get that roadworthied out here at the tip of Africa! Would probably cost me a bottle or two of scotch to get it "through" roadworthy as it has working brakes and lights :-)

Good job and thanks for the smiles.

author
knife141 made it!(author)2011-05-05

Thanks for the kind words! I've had a lot of fun with this contraption.

author
Roto36 made it!(author)2010-09-06

Would like to see more close up pics of the motor mount, sprocket, and rear wheel drive train.
Looks like a fun build!

author
thefutureisnow made it!(author)2010-04-28

 Very cool! I'm gonna build it!

author
anyoldmouse made it!(author)2010-03-18

That is the most awesome thing I've seen in the past 4 minutes.Great job.

author
Greasetattoo made it!(author)2010-01-31

Way to funny!
GReat Job!
LMAO

author
DuctTapeRules%21 made it!(author)2009-12-07

 lol, PETA's gonna kick your arse when they see that from far away :)

author
XOIIO made it!(author)2009-12-17

LOL true!

author
Samuri+Squid made it!(author)2009-12-06

 i love it!

author
knektek made it!(author)2009-12-06

LOL! if someone seen you riding this they would think you are wierd (only because of the monkey.

author
AmyLuthien made it!(author)2009-12-04

BWAHAHAHA!!  That's completely awesome!!  But I've got to know, was beer involved at some point in time?  :D

Thanks posting this! 

author
macrumpton made it!(author)2009-12-04

That is a very cool project. It makes me think of making a version where the motor/battery  is in the monkey part so you could attach it to the back of different vehicles for an electric boost. Put several monkeys in series for more power!

author
tippmannphreak made it!(author)2009-12-03

I gotta stop doing drugs...

author
oppie made it!(author)2009-12-03

Did you use a permanent magnet motor or a series wound? Nice thing about using series wound motors is that they provide enormous torque at startup and can then run up to high speeds. Old school electric trains (the real ones and some of the toy ones) use series wound traction motors for this purpose. For higher speed, the field winding can be weakened with a shunting resistor. Modern railways now use brushless motors.
Have fun riding it. Cool idea.

author
knife141 made it!(author)2009-12-03

It was a PM motor.

author
MW0GKX made it!(author)2009-12-03

I like it!

I'm disabled and have an electric "buggy"  to get about on when I'm not in the car.

I think I may make the monkey part and attach it to the buggy for a laugh!

author
555mst555 made it!(author)2009-12-01

how fast does it go?....and can i make it without the DC controller?

author
knife141 made it!(author)2009-12-01

I geared it low to get enough torque to drive it up a ramp from a standstill.  The top speed is about 12mph, but feels like 40mph because you're sitting so low to the ground.

You probably could make using a heavy duty contactor instead of a controller, but controlling the motor's speed would be difficult -- would either be full on, or full off.  Probably not a good idea.  If you try this, don't use a regular switch, use a high amp contactor.  A regular switch would fry.

author
n1qaw made it!(author)2009-12-02

I had a real old scooter that had basically 4 speeds forward.  It was all contactor controlled series batteries.  each one would be switched in.  The last was like a split of the last cell.  There was a huge wire wound resistor that would cut the top speed some (I guess it would have worked on all the batteries, but they were slow enough as it was, but in high speed, well you wanted to take a bit off the top when cornering)  It was old and simple to work on,  a squeeze throttle and a few relays (more like starter solenoids :)  )    I suspect the last owner had made it out of one of the old 3 wheeled carts.  It was a hoot to zip around in and like you said, 15 or 20 that close to the ground felt like raw speed! lol 

author
aggies made it!(author)2009-12-01

i love the monkey XD

author
Ministryofhate made it!(author)2009-12-01

please for the love of god put a video up...audio synced with this 

http://www.youtube.com/watch?v=6Nh49a8q2E4

or this

http://www.youtube.com/watch?v=V8vINCq_IAI

Christmas has come early my friends.

author
trailleadr made it!(author)2009-12-01

OMGosh, that's the funniest thing I've seen today.
*2 thumbs up*

author
Seleziona made it!(author)2009-12-01

this is sweet!!!

author
Koosie made it!(author)2009-11-30

That's Legend!

I love it, an awesome idea (electric scooter) with a brilliant add on (peddaling ape)!

PS: I like the hat :-)

author
boston09 made it!(author)2009-11-30

can you add pictures of the making of the monkey please.

author
boston09 made it!(author)2009-11-30

lol thats awesome

author
scoochmaroo made it!(author)2009-11-30

Now tell us how to make the hat!

author
knife141 made it!(author)2009-11-30

Yes, I forgot the recipe for the hat:

1 top hat from a haloween costume
1 rolled up pice of cardboard to make the hat stand up
1 string of battery operated lights

Stick the cardboard inside the hat so it stands up and doesn't fall over, and attach the lights with thread & needle.  Then, turn the lights on and listen to your dog bark!

author
Hawkeye+Lyles made it!(author)2009-11-30

Haha, thats awesome !

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Bio: I enjoy taking a pile of junk and making something unusual out of it. I like wheeled vehicles, and currently own two motorcycles, two electric ... More »
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