Update: Segway Clone - Stronger Design Modification

About: I'm an Electrical Engineer with "engineer disease." I need to always be making, fixing or learning about something.

In the original Instructable for the Segway Clone, there is a weak point
at the junction between the vertical PVC pipe and the wood platform. It can crack there if too much sudden force is applied. This Instructable is for modifying that junction to be all metal which strengthens it and PROTECTS you from harm.

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Step 1: Weak Point

In the original Instructable for the Segway Clone, there is a weak point at the junction between the Vertical PVC and the wood platform. If you fall or suddenly put too much force on the handlebars. The mechanical advantage at the fulcrum (intersection) creates a force that is too strong for the PVC. In other words, it cracks as shown in the picture.

Step 2: Parts

Parts Needed:

  • 3/4" Black Iron Floor Flange $5.47
  • 3/4" x 2' Black Iron Pipe $8.51
  • 1-1/4" x 3/4" Black Iron coupling. $3.48
  • 1-1/4" x PVC threaded Male Adapter $0.98

Step 3: Preparation and Assembly

  • Remove any wire connections from the Arduino box. MAKE SURE TO MARK DOWN wire color connections on a paper for reconnection later.
  • Remove the old Floor flange metal from the Segway Clone.
  • Fill holes with Spackle if desired as show in the pic.
  • Cut old PVC as shown in the picture being VERY CAREFUL not to cut the wires.
  • Attach PVC 1-1/4"x3/4" coupler to 3/4" iron pipe as shown in the picture. Use large wrenches to tighten.
  • Attach new Iron Floor Flange to the board.
  • Thread 3/4" iron pipe assembly into board. Tighten with large wrench.

Step 4: Epoxy Handlebars On

  • Take the old handle bar assembly and thread it's wires down the iron pipe through the bottom of the board.
  • Using sandpaper, clean off any paint on the old PVC.
  • Mix up some Epoxy at the 50/50 ratio. Spread it on both sides of the PVC junction and then join them.
  • Be sure the handle bars are parallel with the board front edge.
  • Reconnect the Arduino wiring.

Step 5: Test Ride

  • Wait about an hour for the epoxy to dry.
  • Test ride your newer and stronger Segway Clone!
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    9 Discussions


    2 years ago


    I want to know how you set plans and dimensions for segway.

    Madhan M

    2 years ago

    I am new to this so please explain what are parts are needed and how to connect it


    3 years ago

    Hello, there i am making this project for my final year. I need the complete code and balancing algorithm calculations for this ASAP. please help me.

    1 reply

    Reply 3 years ago

    See link to original Instructable in first sentence.

    Hello, Mine didn't break but I made the modification because of the pvc being so flexable that the Segway would do a slow vibration on pressing the dead-man switch. The mod cured that. Thanks. dwb


    4 years ago

    I'm a Devry university student and I picked your project for a final presentstion can you please tell me how fast it can go and how did you order the wheels with the chain?....thank you I really admire your work ....

    1 reply

    Reply 4 years ago

    Thanks for picking this project.
    I don't know how fast it goes. I recommend a very slow speed. There are no safety mechanisms and the crashes hurt.
    re: the parts, read the Instructable and find the parts list.


    4 years ago

    Hi sir
    I am working on this project.
    So pllz share your experience and challenges which you face during this project.
    So it will help to complete my project.


    4 years ago on Introduction

    Pretty cool little rig. Wish I had the know how to make it work. Very nice. I need a rig for my daughter in Alaska. Has to be bump worthy. (has neuromuscular disease and cant walk very far). Been hemming and hawing about options to try. How about a "mountain" biker, rough terrain version?