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Electric Longboard MarkII

Ground up, over-engineered electric longboard

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I want something under my ass that has enough potential energy packed into its batteries to fire a pound of bacon into the Asteroid Belt.
Since nothing on the market fits the bill; I am building it myself.

With a sufficient disrespect for my own time and money I am learning every EE, ME, CS, Manufacturing technique necessary to complete aforementioned longboard.

The project started in my freshman year of college, Winter 2015.

Mark I was completed in the spring of 2016. It featured a whopping 35mph top speed, a pair of lead-acid scooter batteries giving it a theoretical range of about 4 miles of range, and a jaguaresque construction - requiring field-repairs every 2 miles.

MarkII was started soon after.

My main focus now is to involve more people. I have a few friends helping intermittently, but I think this project can bring together a serious community interested in progressing the field of high-tech DIY electrical vehicles.

P.S Check out the GIT ;)

What we are looking at here is;

12 Hp 4 Wheel Drive - 4 x 6374 2250W BLDC motors

.5kWh battery pack - 64 x ANR26650M1-B LiFeP04 2.4Ah 10C - 12min charge time batteries 

48in x 13 in deck

60 volt system

60mph+ Top speed

40mile+ range

1.5kW charger - 20min charge time.

RGBW headlights - 1000+ Lumens

RGB LED underlighting 

Carbon fiber deck - 500Kg+ load limit

Splash proof

Onboard linux box managing GPS, phone-app connection.

All the files are hosted on the project Git page. This is an open source project.

IMG_3543.JPG

Still gotta do the testing with water cooling. But this is the charger.

JPEG Image - 1.60 MB - 09/02/2017 at 14:35

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Maximum Clearance.png

So I was sitting on a plane with my parents and complained about the lack of clearance, and difficulty i would have in protecting the motors during collision. Needless to say, mom a out-of-the-box thinker.

Portable Network Graphics (PNG) - 802.57 kB - 09/02/2017 at 14:35

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Moulding 1.PNG

I cant spell, but I do know that I will use some thick sheets of MDF and a CNC wood router to create a compression mould for the longboard.

Portable Network Graphics (PNG) - 127.86 kB - 09/02/2017 at 14:35

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  • Adjust

    Danny Andreev5 days ago 1 comment

    Sad news this week. The Techshop has closed. However, I am glad that most of my hardware requiring heavy CNC machinery is finished.

    I have already started to recreate some of the capabilities of the techshop. One such adjustment is a epoxy curing, vaccum press oven in my living room.

    This is the single layer outer shell, its a bit rough around the edges and I am going to redo the layup.

    Roomates have agreed... as long as I keep it clean.

    In other news. The GPS tracking works! the sensor board is outputting gps, and using the google maps api I can overlay my location onto a proper map!

    Lastly:

    I am going to be doing some redesign and try to remove the rest of the hardware manufacture. Since I no longer have access to CNC and metalworking machinery I will have to impovise...

  • The Molds are Done!

    Danny Andreev11/15/2017 at 03:20 0 comments

    The All-Mighty!


    These are a little extra side-project but i still wanted to share :)

  • Molds and Models

    Danny Andreev11/05/2017 at 23:05 0 comments

    A week off of the project due to midterms, and now im back!

    Got a lot of good stuff since the last project log.

    Sensor module is reading in data. The next step is to take the Accelerations,position, velocity and have it plot on a neat interface

    Got the Molds painted, just need to sand, and buff them. Should be ready to do the CF lamination next weekend.

    A decent amount of time went into a side venture. I have a friend who sells finger boards, I made him some molds to speed up the process :)

    I hurt my foot (bruised a metatarsal) So i slapped V1.5 together so I dont have to push when getting to/fro class.

  • 4 Day Weekend

    Danny Andreev10/16/2017 at 21:46 0 comments

    Fall break! you know what that means! just clocked in 50 hours at the techshop in 4 days.

    - Bought Carbon fiber vacuuming stuff

    "hhhnnnnnngggg" - My wallet

    -CNCed the last two molds out of the MDF that I prepped last weekend.

    (All me!)

    -Almost finished the battery pack hardware

    Dat sand blaster tho

    Yea, yea, I know. Steel on aluminum ill figure it out.

    "What exercise equipment do you use?" - "Oh just the  BDB 1340A Jet Lathe"

    -Started on the GPS, Accelerometer, Raspi module!

  • Check your CNC specs!

    Danny Andreev10/08/2017 at 22:21 0 comments

    The 3/4"D 6"L ball endmill does not fit the shopbot... The highest diameter that ER-25 collets go is 1/2"

    Probably for the best since i got 3 exams this week and I gotta study instead of CNCing molds.

    P.S. If you are ever spearing large amounts of glue: buy the non-waterproof version and the largest paint roller they have.

  • Battery Holder Skelton Done!

    Danny Andreev10/01/2017 at 16:28 1 comment

    Another 15 hours at the machine shop this weekend and the aluminum armature is done.

    I finished it off with a sand blasting and it looks sick!

    Next up is the deck :)

  • Manufacturing...

    Danny Andreev09/24/2017 at 18:16 0 comments

    Was legitimately sore after a full day behind a manual mill. Punched holes in all of the battery holders and squared of the edges where the perpendicular grind rails will go.

    Also the MDF mold is finished, I just need to but the carbon fiber lamination supplies and get it waxed. 

  • Production Phase

    Danny Andreev09/17/2017 at 16:36 0 comments

    MarkII is officially in production phase. 

    All the mechanical aspects of the board have been (pretty much) finalized, and I am spending my Saturday nights behind a Tormach CNC mill.

    I am touching up the MDF mold with a set of chisels, and prepping for the vacuuming procedure.

    The issue I am having is that I did not make the truck mounting holes, so the molds are somewhat difficult to align. If I do not figure out how to solve this, It will be back to the CNC wood router for me!

    P.S. Waterjet cutters suck.

    3$/min runtime and they give you a shit finish. Hence my CNCing.

  • CNC Router Mold

    Danny Andreev09/11/2017 at 16:07 0 comments

    I decided that the deck is going to be a 8 layer carbon fiber 12X12 weave with a polystyrene foam core.

    From to to bottom the layers will be C-C-C-F-C-F-C-F-C-C-C

    After spending a few weeks tweaking the final assembly in solidworks and finalizing the deck shape I started making the mold.

    With a couple friend at the architecture school and a few sheets of 3/4" MDF laminated a thick mold which was then handed over to the CNC router.

    Hopefully by the end of the week I can start on the carbon fiber vaccuming operation.

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Discussions

motor_madness84 wrote 11/16/2017 at 02:11 point

Love the project man! Me and my team are currently working on a similar project for a new high powered electric skateboard and we were wondering if you are/have designed your own custom battery management system for your A123 battery pack?

  Are you sure? yes | no

Danny Andreev wrote 6 days ago point

I am about to start designing, youre welcome to help! should be done by the end of the winter.

  Are you sure? yes | no

Neon22 wrote 08/30/2017 at 15:14 point

Have you considered using trucks like Other planet revolution. much stabler at high speed. flat spot in the middle.

Also I have inkscape based worksheet for batts through to drivetrain with HTD belt torque calcs integrated.

but needs looking over as I have an error (at least one :) somewhere... Output looks like:

inkscape electric drivetrain

  Are you sure? yes | no

Danny Andreev wrote 09/01/2017 at 15:38 point

Those trucks look sick! I may pick a pair up and look into switching over in the next  board version.
PM me about the work on batteries, im interested

  Are you sure? yes | no

Rod Hower wrote 08/29/2017 at 18:45 point

I may be able to help with the motors, I work at Ametek-Rotron and design BLDC motors and controls.  We bought Extreme Motors about 8-10 years ago and continue designing that product from our Kent, Ohio location.

  Are you sure? yes | no

Danny Andreev wrote 08/29/2017 at 18:47 point

No way! That is amazing, PM me your email, we alreadu have 3-4 guys on board.

  Are you sure? yes | no

Marco wrote 08/23/2017 at 08:38 point

i'm learning bldc drv and wanna join your team

  Are you sure? yes | no

Danny Andreev wrote 08/23/2017 at 17:32 point

PM me, lets chat

  Are you sure? yes | no

Marco wrote 08/23/2017 at 05:23 point

i wanna know bldc drive schema...

what's the status of the project?

  Are you sure? yes | no

Danny Andreev wrote 08/23/2017 at 17:32 point

currently using Vedder's VESC controller (its an open source bldc driver) i plan on updating his design (eventually) to fit better with my board.

  Are you sure? yes | no

Peter wrote 08/23/2017 at 01:31 point

Do you have a source and/or price for the batteries and charger?  Or for the BOM in general?

  Are you sure? yes | no

Danny Andreev wrote 08/23/2017 at 17:35 point

I am buying the batteries from A123, they are a manufacturer in Detroit. Me and a friend are designing the charger ground up, by ourselves. Latest iteration delivared 900W. I will eventually go through my digikey purchases and add the BOMs to the git page.

  Are you sure? yes | no

Aaron_Kraus wrote 08/22/2017 at 18:21 point

wait... WHAT? 90+ kph? ryly O_o

Must... not... buy... all... parts

As soon as my other 4 Projects are half baked, i'll start with this

My fastest run on my Board was at the Gravity Festival 2015 in NZ with 72-75  kph.

But that was Downhill, I always dreamed of a board like this :)

[EDIT] another Solidworks guy and all source files *Thumbs up*

  Are you sure? yes | no

Danny Andreev wrote 08/22/2017 at 19:16 point

Much love! I am definitely interested in collaborating, so hit me up if you good some good ideas.

  Are you sure? yes | no

Aaron_Kraus wrote 08/24/2017 at 19:48 point

How far developed is your Project at the moment?

Did you build all that drivechain already?

I go thru your SW files and they look really good, I'm doing cad with sw since 2006 and can't find much to criticize :p 

  Are you sure? yes | no

Danny Andreev wrote 10/01/2017 at 15:26 point

I have a lot of the electronics finished, but working on the mechanical/hardware revision right now. I have a V1.5 drivetrain (check the pics) working on V2. 

Appreciate it! Iv been CADing for some years now as well :)

  Are you sure? yes | no

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