Diy Electric Scooter Petrol To Electric Conversion

instructables
Diy Electric Scooter Petrol to Electric Conversion and Modification
by shalbk
Hi
In this project, I have taken an old petrol scooter and converted it to electric green vehicle and heavily modified it.
The entire project was a fun build and I hope you guys will love this instructable.
https://youtu.be/Y4fkVko8Jpw
Step 1: Look of the Vehicle Before and After
I took the old vehicle, type an automatic scooter, of TVS make here in India form Indian manufacturer. The vehicle
was in very bad shape. I stripped down the entire vehicle up to chassis and worked entirely on its chassis.
Diy Electric Scooter Petrol to Electric Conversion and Modification: Page 1

Step 2: Removing All Internal Combustion Engine Parts and Body Parts and Custom
Parts
I removed all the Internal combustion engine parts like head block, piston, crankshaft, air filter, magneto assembly
to name few of them. Also, all the body parts were removed and all custom parts as shown in the picture were
made. Some parts were made by cutting old body panels of the company and the rest was made from the 6inch
PVC pipes after heating it and molding it and got it colored white
Step 3: Engine Electrification and Custom Parts
An adapter plate from aluminum was made to fix the pictures the custom shaft will couple from fan side to
motor on the fan side of the crank case as shown in the motor with the toothed nylon transmission geared
the above picture. A custom crankshaft was also drive. The adapter plate will get mounted from the fan
made out of the iron bar because we do not want the side of the engine as seen in the picture. Also, the
offset weight to rotate unnecessarily and imbalance 3000w BLDC motor and steel plate to seal the empty
the entire system as there is no need of one as there went of engine block place is shown as above.
is no piston in the electric engine. As seen in the

Step 4: Assembling the Electric Engine
The electric engine assembly was then started. The so-called CVT drive as its really very lossy drive and I
motor was mounted on the adapter plate. Connecting did not want to lose a single watt in that. The rear
gears mounted on both motor and driveshaft. The reduction gearbox was kept intact and the shaft was
well-greased nylon coupler is then inserted in modified to have a key slot to fix pulleys on front and
between the shaft and motor. The motor is then rear shafts. The tensioner pulley was fixed at the
placed in the alignment of the driveshaft and is bolted center and it was then given appropriate tension on
firmly on to the crankcase body of the engine. On the the belt drive.
opposite side, we will get the output of the shaft and
here I have removed the automatic variable drive or

Step 5: Finalizing the Electric Engine
The CVT side engine cover was again fixed at a place to protect the belt drive. Steel plate was fixed at the empty
place from where engine block was removed so that dust and other environmental things do not get inside the
engine compartment. The wheel was fixed and the stand was also installed on which the electric engine is parked.
Step 6: Installing the Engine to Frame and Battery
The engine was then mated to frame. All custom body panels were installed and as shown in the picture the
uneven surfaces of the luggage compartment were flattened with the grinder to make it level to accommodate 12v
28Ah four batteries in the bay.

Step 7: The Final Out Come
Agile look is given to the previously soft-looking traditional scooter. I think that we were able to make it look like
that quite successfully. So what do you guys think do let me know your views.

Step 8: Lets Take It for a Spin
Guys the scooter is really very very fun machine to understand the content of the entire video. I hope that
ride. It has ample power to propel the scooter at the you loved reading this instructable. I am thankful for
speed of about 55Kmph. Feels sturdy and safe to reading this till the end and comment from all of you
ride. The entire video is available on youtube. If you will really be a matter of appreciation to the hard
are interested in how it performs on road do take a work. Thank you all.
look at it. I have placed English subtitles in the video
so that though it's in Hindi you will be able to
Well thought out and good use of available materials and batteries. I think the "55Kmph" is
probably a bit optimistic and from what I understand about traffic in India, dangerous. (Kidding!)
55mph is pretty good and about as fast as I want to be on a scooter. 55kph would be about 35 in
American Speed Units*, or more what I'd expect. I have a friend I'm trying to talk out of a dead
Honda scooter to do something like this. Enjoy! (* just made that up.)
Thank you for warm word of appreciation
Nice job man, but aren't lead acid too heavy?

What's the top speed on that?
Looked at it...Thought, that looks a lot like my scooter.

Thought, that can't be possible, it's really hard to get lithium batteries in India.
read the artcle, It is indeed the same tvs scooter as mine.
Discovered it's lead acid.
I forgot to mention you the top speed it is 55kmph and definitely lead acid batteries are heavy but
cheap for prototype as well so I used those batteries. This scooter gives me ample of power and
range of about 45kmpc so I think it's quiet respectable figure.Thanks for your time and interest
First of all thanks for warm appreciation. My second bajaj boxer is almost ready and I am going to
use lifepo4 battery pack home made in that. Now getting battery pack is not that expensive as
before and things are going to ease off more in India for getting your hands on to some batteries for
your DIY EV projects. My channel is techtube360 on YouTube stay tuned for more. Feel free for
any help
Great work -Neat designing.
When you are able to switch to LFP batteries you will really notice it as there is no voltage sag and
more useable capacity.
https://www.facebook.com/groups/271980786862023/?ref=bookmarks

Ya soon I am going to install LFP in this build and expected range is about to go up by almost 60%
Will try putting that instructable here. Thanks for appreciation.

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instructables

Diy Electric Scooter Petrol to Electric Conversion and Modification

Step 1: Look of the Vehicle Before and After

Diy Electric Scooter Petrol to Electric Conversion and Modification: Page 1

Step 3: Engine Electrification and Custom Parts

Diy Electric Scooter Petrol to Electric Conversion and Modification: Page 3

Diy Electric Scooter Petrol to Electric Conversion and Modification: Page 4

Step 6: Installing the Engine to Frame and Battery

Diy Electric Scooter Petrol to Electric Conversion and Modification: Page 6

Diy Electric Scooter Petrol to Electric Conversion and Modification: Page 7

Nice job man, but aren't lead acid too heavy?

Looked at it...Thought, that looks a lot like my scooter.

Diy Electric Scooter Petrol to Electric Conversion and Modification: Page 8

Diy Electric Scooter Petrol to Electric Conversion and Modification: Page 9

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