An Electric Vehicle Conversion With A Difference

October 30, 2024 by Jenny List 25 Comments

For a first try at an electric vehicle conversion we’re guessing that most would pick a small city car as a base vehicle, or perhaps a Kei van. Not [LiamTronix], who instead chose to do it with an old Ferguson tractor. It might not be the most promising of EV platforms, but as you can see in the video below, it results in a surprisingly practical agricultural vehicle.

A 1950s or 1960s tractor like the Ferguson usually has its engine as a structural member with the bellhousing taking the full strength of the machine and the front axle attached to the front of the block. Thus after he’s extracted the machine from its barn we see him parting engine and gearbox with plenty of support, as it’s a surprisingly hazardous process. These conversions rely upon making a precise plate to mount the motor perfectly in line with the input shaft. We see this process, plus that of making the splined coupler using the center of the old clutch plate. It’s been a while since we last did a clutch alignment, and seeing him using a 3D printed alignment tool we wish we’d had our printer back then.

The motor is surprisingly a DC unit, which he first tests with a 12 V car battery. We see the building of a hefty steel frame to take the place of the engine block in the structure, and then a battery pack that’s beautifully built. The final tractor at the end of the video still has a few additions before it’s finished, but it’s a usable machine we wouldn’t be ashamed to have for small round-the-farm tasks.

Surprisingly there haven’t been as many electric tractors on these pages as you’d expect, though we’ve seen some commercial ones.

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A Practical Electric Motorcycle, Made From A Motorcycling Classic

March 28, 2021 by Jenny List 26 Comments

If you were to try to name the vehicle that brought transport to the world’s masses, where might you start? The Ford Model T perhaps, or maybe the VW Beetle? If this was the direction you took, then we’re sorry to say you aren’t even close. The answer lies in Soichiro Honda’s Dream and its descendants, small cheap and reliable motorcycles that have been manufactured in their many millions in some form continuously for over seven decades, and which have been sold in every country in the world that has any form of road. They may be unglamorous, but if you had to pick a bike to circumnavigate the globe they can be fixed by a local mechanic anywhere on the planet. That little horizontal single-cylinder engine may be reliable though, but it’s hardly green. [David Budiatmaja] has fixed that, by transforming an elderly Honda C70 into an electric motorcycle worthy of a 21st-century city (Indonesian, Google Translate link).

The conversion appears to have achieved wide coverage in the Indonesian motoring press, and there’s more about it in the video we’ve placed below the break (Indonesian, you may have to enable subtitle translation). The C70 has been stripped of its fairing, engine, and gearbox, and a wheel motor has been laced into the rear rim. There are three battery packs made from surplus 18650 cells, and an ammo can top box containing most of the electrical wiring. Driven at 72V, it gives a modest top speed that isn’t exactly fast but isn’t too bad on a city bike. A set of trail bike bars replaces the stock ones, and something of a cosmetic makeover has given it a tougher image than your local pizza delivery bike. If it didn’t still sport the C70’s somewhat archaic front forks, it might be easy to mistake it for something else entirely.

If wheel motor motorcycle conversions interest you, this isn’t the first one we’ve brought you.

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Failed Scooter Proves The Worth Of Modular Design

June 24, 2019 by Tom Nardi 17 Comments

Like many mechanically inclined parents, [Tony Goacher] prefers building over buying. So when his son wanted an electric scooter, his first stop wasn’t to the toy store, but to AliExpress for a 48V hub motor kit. Little did he know that the journey to getting that scooter road-ready would be a bit more involved than he originally bargained for.

Of course, to build a motorized scooter you need a scooter to begin with. So in addition to the imported motor, [Tony] picked up a cheap kick scooter on eBay. Rather than worrying about the intricacies of cleanly integrating the two halves of the equation, he decided to build a stand-alone module that contained all of the electronics. To attach it to the scooter, he’d cut off the rear wheel and literally bolt his module to the deck.

[Tony] goes into considerable detail on how he designed and manufactured his power unit, from prototyping with laser cut MDF to the final assembly of the aluminum parts that he produced on a CNC of his own design. It’s really a fantastic look at how to go from idea to functional device, with all the highs and lows in between. When the first attempt at mounting the battery ended up cutting into the 8 Ah LiPo pack for example, and treated his son to a bit of a light show.

With all the bugs worked out and his son happily motoring around the neighborhood, [Tony] thought his job was done. Unfortunately, it was not to be. It turned out that his bolt-on power unit had so much kick that it sheared the front wheel right off. Realizing the little fellow didn’t have the fortitude for such electrified exploits, he went to a local shop and got a much better (and naturally much more expensive) donor for the project.

It’s here that his modular approach to the problem really paid off. Rather than having to redesign a whole new motor mount for the different scooter, he just lopped the back wheel off and bolted it on just as he did with the cheapo model. What could easily have been a ground-up redesign turned out to be a few minutes worth of work. Ultimately he did end up machining a new front axle for the scooter so he could fit a better wheel, but that’s another story.

Scooters would seem to be the unofficial vehicle of hackers, as we’ve seen a long line of hacked up two-wheeled rides over the years. From relatively low-key modifications of thrift store finds, to street-legal engineering marvels. We’ve even seen scooters fitted with trailers, so even the tiniest of proto-hackers can come along for the ride.

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Electrifying A Vintage Outboard Motor

January 10, 2019 by Tom Nardi 14 Comments

Clamped or bolted to the stern of the boat, outboard motors offer a very easy and (relatively) economical way of powering small craft. The vast majority of these outboards are gasoline powered, with electric models generally limited to so-called “trolling motors” which are often used to move slowly and quietly during fishing. That might be fine for most people, but not [Olly Epsom].

An engineer focusing on renewable energy by profession, [Olly] wanted to equip his small inflatable dinghy with a suitably powerful “green” propulsion system. Deciding nothing on the market quite met his requirements, especially for what manufacturers were charging, he decided to convert an old gas outboard to electric. Not only did he manage to do it for less money than a turn-key system would have cost, but he ended up with a system specifically geared to his exact requirements. Something he says will come in handy if he ever gets around to converting the dinghy to remote control so he can use it as a wildlife photography platform.

Put simply, an outboard motor consists of a gasoline engine with a vertical shaft that’s coupled to a right-angle gearbox with a propeller on the end. Beyond that they’re a fairly “dumb” piece of gear, so replacing the engine on top with something else should be (at least in theory) a pretty simple job. Especially on the small older model that [Olly] decided to use as a donor unit. The 1974 Johnson 2 HP motor didn’t have any tricky electronics in it to contend with; the thing didn’t even have a clutch.

Once [Olly] had removed the old gas engine from the top of the outboard, he designed an adapter plate in OnShape and had it cut out of aluminum so he could mount a beefy 1 kW 48 V brushless electric motor in its place. Connecting the new electric motor to the carcass of the outboard actually ended up being simpler than putting the original motor on, as this time around he didn’t need to reconnect the cooling pumps which would usually pull water from down by the propeller and recirculate it through the engine.

While the mechanical aspects of this project are certainly cool, we’re especially interested in the control system for this newly electric outboard. It uses a 3.2 inch Nextion color touch screen and Arduino Nano to provide a very slick looking digital “dashboard” which can convey motor status and other information at a glance. Unfortunately, [Olly] says the details on that part of the project will be saved for a future post, leaving us with only a single picture of the system’s interface for us to drool over until then.

We’ve seen the occasional seafaring project that made use of an electric trolling motor, and we’ve even seen an electric drill put in some overtime spinning a prop in the water. Converting gasoline boat over to electric is however a rarity. But much like electric car conversions, such projects may become more common as the cost and complexity of powerful electric propulsion systems continues to fall.

[Thanks to Alex for the tip.]

Why Converting Classic Cars To Electric Drive Is A Thing

January 4, 2019 by Lewin Day 96 Comments

A vintage British sportscar is a wonderful thing. Inimitable style and luxury, beautiful curves, and a soundtrack that could make even Vinnie Jones shed a tear. However, even under the most diligent maintenance schedule, they are known, above all, for their unreliability. As the value of such cars is tied heavily to their condition as unmodified examples, owners are typically reluctant to make modifications to remedy these issues.

However, things are starting to change. Cities across the world are enacting measures to ban fossil fuel vehicles from their streets, and sales of such vehicles are similarly going to be banned entirely. The automotive industry is preparing for a major pivot towards electric drivetrains, and no carmaker will be left untouched. In this landscape, it’s not just Tesla and Nissan who are selling electric cars anymore. Luxury brands are beginning to deliver electric vehicles, too.

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Curbside Mower Gets Electric Transplant

December 8, 2017 by Tom Nardi 28 Comments

There’s few things more exciting to a hacker or maker than seeing a piece of hardware on the curb. An old computer, an appliance, maybe if you’re really lucky some power tools. So we can only imagine the rush that known lawn equipment aficionado [AmpEater] had when he saw a seemingly intact push mower in the trash. The pull start was broken on the gas engine, but where this mower was going, it wouldn’t need a gas engine.

When he got the mower back to his garage, he started on the process of converting it over to electric. Of course this means basically everything but the wheels, handle, and deck would get tossed. But starting with a trashed gas mower still sounds a lot easier compared to trying to figure out how to make or source a wheeled mower deck.

Step one in this conversion was stripping all the paint off the deck and welding a plate over where the original gas engine was. [AmpEater] then 3D printed some mounts to hold the DeWalt tool batteries he would be using as a power source, taking the extra time to align everything so it would have the look of an old flathead gasoline engine. A tongue-in-cheek reference to the mower’s old gasoline gulping days, and an awesome little detail that gives the final product a great look.

The controller is a commercial model intended for electric bikes, and the heart of this new mower is a brushless direct-drive motor capable of 3,000 RPM at 40 A. [AmpEater] reports a respectable one hour run time with the six DeWalt batteries, and more power than his store-bought Ryobi electric mower.

If the name [AmpEater] looks familiar, it’s because this isn’t the first time he’s graced us with a mower conversion: back in 2013 he impressed us with his solar-electric Cub Cadet zero-turn. This build isn’t quite as slick as the Cub Cadet, but the much lower cost and difficulty level means that you may be able to follow in his footsteps even if you don’t have his Zeus-level mastery of the electric motor.

As electric mowers have gotten more popular, we’ve seen an increasing flow of hacks and mods for them. Everything from replacing the batteries to turning them into something else completely.

Sealed-System Bucket Loader Cleans Messes In Dangerous Places

May 20, 2014 by Mike Szczys 23 Comments

[youtube=https://www.youtube.com/watch?v=XjHJ71SVop4&w=580]

Cleaning up after a disaster is hard and dangerous. But the ROEBL project is trying to make it substantially safer by removing the human operator from harm’s way. The Remote Operated Electric Bucket Loader had a big double-fenced, cement barrier play area set up at Maker Faire and [Justin Gray] walked us through the project which concluded with a demonstration of the hardware.

For now the operator does need to be on site to see what the loader is doing, but a first-person video setup is planned for the future. Still, removing the operator from the jarring experience of riding inside is an improvement. And the sealed nature of the electric and hydraulic systems mean that it can operate in areas inundated with liquids like water or oil.

The video above has a 90 second demonstration at the end (while we all laugh like children at what really was a giddy display of power being thrown about by a handheld controller). The ROEBL website has a gallery where you can see the conversion process that started with a standard diesel machine.