1. EML 4501 – Mechanical System Design
Design Report 3
Design Group 6:
Jose Cortes
Laura DeTardo
Matthew DeVries
Jonathan Franco
Massimiliano Giffuni
Matthew Vitarelli

2. Table of Content
Executive Summary………………………………………… 1
Introduction…………………………………………………. 2
Operation and Use…………………………………………... 3-13
Safety Precautions…………………………………………... 14
Material and Fabrication……………………………………. 15-20
Fabrication Processes……………………………………….. 21-22
Assembly Process
Assembly Steps………………………………………….. 23-59
Handling and Insertion Times…………………………… 60-62
Performance Analysis………………………………………. 63-68
Mechanical Analysis
Frame Loading Analysis………………………………… 69-76
Chain Drive……………………………………………… 77-78
Brake Assembly………………………………………… 78-80
Thermal Analysis…………………………………………… 81-82
Electrical and Control Analysis……………………………... 83
Parts Lists
Standard Parts List………………………………………. 84-85
Custom Parts List………………………………………... 86-87
Cost Analysis……………………………………………….. 88-91
Appendix A: SolidWorks Drawings………………………... 92-161
Appendix B: Cost Analysis…………………………………. 162-183
Appendix C: Insertion and Handling Charts………………... 184-186

3. Executive Summary
This design report outlines our seamlessly constructed high-end electric scooter. The
design process required countless hours of brainstorming, analyzing, and perfecting the design,
as well as a vast wealth of engineering knowledge. Our product, the Electric Slide, is a
lightweight electric scooter with excellent performance capabilities that is designed and built
with the ability to fold and collapse into itself, making it a compact and convenient product for
the average consumer. The Electric Slide targets the young teenage consumers seeking a fun
mode of transport, college students that need a compact vehicle to get to classes on time, and
adults that go to work everyday. The specs of our design are unrivaled, but what sets our scooter
apart from the competitors is the way it can fold and fit inside a carry-on suitcase. The Electric
Slide places no limitations on the user in terms of specs and storage, and using an electric battery
appeals to the “green” market of the 21st
century.
Throughout the design process, the important unique aspects of the Electric Slide were
given heavy consideration. When compared to other electric scooters on the market such as the
well-known Razor E300, the Electric Slide is half the weight and can produce twice the torque,
while achieving up to 45 minutes of continuous run time at a similar maximum speed. When
discussing performance and weight, the Electric Slide already has a huge advantage over the
competition. Additionally, our revolutionary scooter is one of a kind with its folding mechanism
that allows the scooter to be folded into a compact configuration for easy transport. The folding
mechanism is simple to use – it can be folded and unfolded without tools in seconds! In its
folded configuration the Electric Slide fits comfortably in the standard carry-on suitcase
dimensions of 24” x 12” x 9”. As stated above, it is environmentally friendly; not only is it
electric but its structure is made out of magnesium alloy and it is powered by a 6S Li-Po battery.
Magnesium is known to be a fully recyclable metal and Li-Po batteries can be thrown away if
discharged properly. Overall, the Electric Slide can adapt to any lifestyle with a high torque
that’s rated to move any individual of any weight at maximum speed, and better stall torque to
move uphill. Although our company is based in the flat state of Florida, the Electric Slide can
adapt to many different environments and will prove to be the ultimate scooter for you.
Designed as a high-end scooter with many great features the Electric Slide has a
manufacturing cost of $992.13 and a sales price of $1,979.99. With 100,000 scooters in
production this can potentially generate $98,7860,000 in profits.
Group 6 pg. 1

4. Introduction
This design report reviews the Electric Slide scooter and its individual parts. Included are
an explanation of the operation and use for the scooter, a list of safety precautions, materials and
fabrication processes, the assembly process, a detailed analysis of multiple systems of the
machine and a cost analysis for the scooter.
The operations goes over how the scooter should be operated and how to fold and unfold
the scooter. The list of safety precautions provides an overview of the design process with
respect to hazards we wanted to avoid when constructing this scooter.
The material and fabrication specifies the materials of the individual components and
highlights the fabrication processes for the custom-made parts. There are small descriptions
explaining how those processes are done.
The assembly process contains diagrams with written instructions along with a chart of
the handling and insertion times to give an estimate of the overall time to manufacture the
complete scooter.
A comprehensive analysis was implemented to evaluate the mechanical, thermal, and
electrical components of the scooter. The performance analysis covers stall torque of the motor,
top speed, and battery life.
The cost analysis reviews the prices of the individual off-the-shelf parts, as well as how
the prices of the custom parts were estimated.
Group 6 pg. 2

5. Operation and Use
The Overall Scooter
The scooter is put into motion through a three step process. First, the throttle is
twisted which sends an electrical signal through the throttle cable into the controller. The
controller then uses power from the batteries to send a signal to the motor. Finally, the
motor converts the electrical signal from the controller into mechanical power, through
the rotation of its shaft and sprocket, which powers the drive train. To stop, the brake
handle is compressed which pulls the brake cable. When the brake cable is pulled
forward it in turn compresses the brake caliper creating friction against the brake drum
slowing down the wheels. To support the weight of a rider, the scooter’s design disperses
the load over the deck and frame so there is no concentrated load on a single element of
the scooter’s frame. [Design Report 2]
Scooter Collapsing Process
Step 1
Simultaneously rotate both folding deck locator in the directions of the arrows as shown.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 3

6. Step 2
Flip the folding deck onto the rear deck plate.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 4

7. Step 3
Firmly press down the button connector at location 1, and simultaneously slide the top
telescoping tube into the second tub. Then repeat this process for locations 2-4.
𝛼 = 360° 𝛽 = 360°
Step 4
Place the thumb of the right hand at location 1, and the thumb of the left hand at same
location on the other arc. Wrap the index and middle fingers of right hand around the
underside of the lock rod at location 2, and same fingers of other hand on other side of
rod. Pull the rod in the direction of the red arrow. When the rod is raised to its highest
point, follow the direction of the orange arrow, and lower the rod into location 3.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 5

8. Step 5
Using both hands, simultaneously press down the button connectors at location 1, and
slide the front section in the direction of the red arrow. Use both hands to then
simultaneously press the button connectors at location 2. Slide the front section and align
the hole with location 2, locking it into place with the button connectors.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 6

9. Step 6
Similarly to the previous step, press down the button connectors of the rear frame
assembly at location 1. Slide back and align the holes with the buttons at location two,
locking the rear assembly into place.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 7

10. Step 7
Push down the button connectors denoted by the orange arrows and pull out the handle
bar assemblies in the direction of the blue arrows. Place both handlebar assemblies on the
deck of the scooter.
𝛼 = 360° 𝛽 = 360°
The scooter is now fully collapsed.
Group 6 pg. 8

11. Scooter Unfolding Process
Step 1
Press down the handlebar button connectors and insert the handlebar in the top
telescoping tube, aligning the holes and locking into place with the button connectors.
𝛼 = 360° 𝛽 = 360°
Step 2
Using both hands, simultaneously press the button connectors at location 1 and slide the
front section in the direction of the arrow. Press down the button connectors
simultaneously at location 2, and lock the front section into place, aligning the front
section holes with the button connectors.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 9

12. Step 3
Use both hands to simultaneously press down the button connectors at location 1 and
slide the rear section in the direction of the arrow. Press the button connectors at location
2 simultaneously, and slide the rear section, locking it into place with the button
connectors at location 2.
𝛼 = 360° 𝛽 = 360°
Step 4
Place the thumb of the right hand at location 1, and thumb of left hand at same location of
other arc. Place the index and middle fingers of right hand at underside of location 2, and
the same fingers of other hand on the other side of rod. Pull the rod in the direction of the
red arrow. When the rod is raised to its highest point, follow the direction of the orange
arrow, and lower the rod into location 3.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 10

13. Step 5
Holding tube 4 with the dominant hand, pull in the direction of arrow, locking the button
connector in place in rod 3. Continue pulling the remaining three tubes until all the tubes
are locked into place with respect to the fork.
𝛼 = 360° 𝛽 = 0°
Step 6
Flip the folding deck in the direction of the arrow and onto the frame rails.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 11

14. Step 7
Simultaneously rotate both of the folding deck locators in the direction of the arrows and
rest them over the deck.
𝛼 = 360° 𝛽 = 360°
The scooter is now ready to ride!
Group 6 pg. 12

15. Table 1: Folding Handling and Insertion Times
Total Folding Time: 49.45 seconds
Table 2: Unfolding Handling and Insertion Times
Total Unfolding Time: 58.35 seconds
Handling Insertion
Step Alpha Beta Alpha +
Beta
# of
Occurrences
Handling
Time
Step
Time
Source # of
Occurrences
Insertion
Time
Step
Time
Source
1 360 360 720 2 1.95 3.9 (3,0) 2 1.5 3 (0,0)
2 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)
3 360 0 360 4 1.5 6 (1,0) 4 1.5 6 (0,0)
4 360 360 720 1 5.6 5.6 (8,3) 1 2.5 2.5 (0,1)
5 360 360 720 1 3 3 (9,1) 1 2 2 (3,0)
6 360 360 720 1 3 3 (9,1) 1 2 2 (3,0)
7 360 360 720 2 3 6 (8,3) 2 1.5 3 (0,0)
Total Time: 29.45 20
Handling Insertion
Step Alpha Beta Alpha +
Beta
# of
Occurrences
Handling
Time
Step
Time
Source # of
Occurrences
Insertion
Time
Step
Time
Source
1 360 360 720 2 1.95 3.9 (3,0) 2 5 10 (3,1)
2 360 360 720 1 3 3 (9,1) 1 2 2 (3,0)
3 360 360 720 1 3 3 (9,1) 1 2 2 (3,0)
4 360 360 720 1 5.6 5.6 (8,3) 1 2.5 2.5 (0,1)
5 360 0 360 4 1.5 6 (1,0) 4 2.5 10 (2,0)
6 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)
7 360 360 720 2 1.95 3.9 (3,0) 2 1.5 3 (0,0)
Total Time: 27.35 31
Group 6 pg. 13

16. Safety Precautions
 Using our previous knowledge from the Razor E300 scooter, we came to the conclusion
that the On/Off throttle (bang-bang controller) was not as safe for younger riders as a
proportional throttle. By using a proportional controller the user can control the
acceleration of the scooter when in use, as high accelerations can potentially result in
injury if maneuverability of the scooter is lost.
 It should be noted that the Lithium Polymer battery used in this scooter should not be
drained below 3 volts or it could cause permanent damage to the battery. By the inclusion
of a low voltage cutoff indicator the user is able to know when it is suggested to turn off the
scooter due to safety precautions.
 We felt that it was important to use as many eco-friendly materials as possible when
designing this scooter. With that in mind, Lithium Polymer batteries can be disposed of in
the trash with no harm to the environment when discharged properly. All parts made of
magnesium alloy and polypropylene can be melted down and reused.
 When reviewing our original design concept, it was noted that a space on the deck could be
dangerous as it was large enough for a foot to slide through and become stuck under the
scooter while in operation. To fix this issue, we added an additional deck plate to ensure
there would be no holes. The deck plates folds by the use of a hinge, that way we can fold
and unfold the scooter within the required dimensions. To keep the front deck plate from
bouncing during operation, a set of metal strips rotate to hold the plate to the frame.
 Rider comfort is always very important. By using the ergonomics of the design and the
damping capacity of the magnesium alloy used in the structural frame of the scooter, the
rider can have a safer and more pleasant ride. As magnesium alloy absorbs bumps and
shocks better than aluminum or steel, the user feels the vibrations less on the hands and
body. The grip of the scooter could potentially cause injury on the rider or pain if the user
is not accustomed to it. Too many vibrations could result in extreme discomfort in the
hands or other parts of the body. The air-filled inner tire tubes also help improve the rider’s
comfort and vibration absorptions of the road.
 The folding mechanism assembly is designed in a way that prevents the folding mechanism
from being free while it is unfolded into its riding mode. The lock rod stays in place by the
inclusion of the clips which keep the rod from rotating and the spring which applies a
downward force. This downward force prevents the lock rod from moving up and
potentially causing danger to the rider if the handle assembly moved by folding.
 The two side guards around the rear axle mechanisms prevent the user or anyone else from
reaching into the rotating mechanisms which can cause serious injury. Side guards protect
the motor assembly as well.
 The battery box works as a protective barrier to the battery and the other electrical
components. Water could create some shock to the user and the battery box is made of a
plastic that prevents this from happening. Also, it protects the battery from bumps or other
environment hazards that could cause the electrical components to explode or ignite.
 The grips of the handle bar are made out of silicone rubber material. This rubber material
allows for the user to form a good grip with the scooter, thus preventing any slippage that
could result from bumps or harsh turns.
 Aside from preventing dirt from getting accumulated inside the frame rail sets, the frame
end caps also hide the sharp edges of the rails that resulted from the manufacturing process.
Group 6 pg. 14

17. Material and Fabrication
Frame:
 End Caps - Polypropylene
Polypropylene (PP) is a highly versatile plastic with a fairly low density and low cost. PP
can be used in many molding and extrusion processes. It is flexible and impact resistant
so that it can withstand any rocks or debris it may come in contact with when operating
the scooter so that nothing gets inside the frame of the scooter. An added benefit is that
polypropylene can be dyed without degrading the integrity of the material.
[Source: http://composite.about.com/od/Plastics/a/What-Is-Polypropylene.htm]
Fabrication Process: Plastic Injection Molding
 Button Clips – Steel
Steel is used because it provides structural integrity to the part without adding a large
amount of additional weight. The zinc-plating on the exterior provides good corrosion
resistance for a part that will be exposed to the elements.
 Tubes- Magnesium Alloy
These parts are manufactured using a magnesium alloy. This metal was chosen for its
high strength to weight ratio and ease of machinability. Magnesium is the lightest
structural metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its
material properties give it a high damping ratio so that it reduces the vibrations
transferred to the hands and feet of the rider. In addition, magnesium has good fatigue
and dent resistance which allows the scooter parts to last longer without wearing out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Extrusion and welding
 Deck Plates- Magnesium Alloy
These parts are manufactured using a magnesium alloy. This metal was chosen for its
high strength to weight ratio and ease of machinability. Magnesium is the lightest
structural metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its
material properties give it a high damping ratio so that it reduces the vibrations
transferred to the hands and feet of the rider. In addition, magnesium has good fatigue
and dent resistance which allows the scooter parts to last longer without wearing out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Extrusion
Folding Mechanism:
 Arc – Magnesium Alloy
This part is manufactured using a magnesium alloy. This metal was chosen for its high
strength to weight ratio and ease of machinability. Magnesium is the lightest structural
metal, it is 76% lighter than steel and 20 times stronger than thermoplastics. Its material
properties give it a high damping ratio so that it reduces the vibrations transferred to the
Group 6 pg. 15

18. hands and feet of the rider. In addition, magnesium has good fatigue and dent resistance
which allows the scooter parts to last longer without wearing out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Die Casting and welding to attach to frame
 Folding Spring – Steel
Steel was used for the spring for its ability to withstand repetitive motions without
breaking. It is also pliable when in wire form so it aids in the ability to form coils without
unwinding.
Fabrication Process: CNC Machine
Handlebars:
 Grips – Silicon Rubber
Silicone was used for the grips for its anti-slip properties, this keeps the riders hands from
coming of the handlebars when operating the scooter. Silicone also has a high resistance
to tearing so that the grips will not wear out during the life of the scooter.
Fabrication Process: Liquid Injection Molding
 Brake Lever – Polypropylene
Polypropylene (PP) is a highly versatile plastic with a fairly low density and low cost. PP
can be used in many molding and extrusion processes. It is flexible and impact resistant
so that it can withstand continual use while operating the scooter. An added benefit is that
polypropylene can be dyed without degrading the integrity of the material.
[Source: http://composite.about.com/od/Plastics/a/What-Is-Polypropylene.htm]
Fabrication Process: Plastic Injection Molding
 Throttle – Polypropylene
Polypropylene (PP) is a highly versatile plastic with a fairly low density and low cost. PP
can be used in many molding and extrusion processes. It is flexible and impact resistant
so that it can withstand continual use while operating the scooter. An added benefit is that
polypropylene can be dyed without degrading the integrity of the material.
[Source: http://composite.about.com/od/Plastics/a/What-Is-Polypropylene.htm]
Fabrication Process: Plastic Injection Molding
Drive Train:
 Motor Mount – Magnesium Alloy
This part is manufactured using a magnesium alloy. This metal was chosen for its high
strength to weight ratio and ease of machinability. Magnesium is the lightest structural
metal, it is 76% lighter than steel and 20 times stronger than thermoplastics. Its material
properties give it a high damping ratio so that it reduces the vibrations transferred to the
Group 6 pg. 16

19. hands and feet of the rider. In addition, magnesium has good fatigue and dent resistance
which allows the scooter parts to last longer without wearing out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Die Casting and welding
 Motor- Steel
The motor is made of steel. The motor creates a large amount of heat and needs to consist
of a material that will not warp or deform under those temperatures. Steel creates a rigid
component that can withstand the weight of the internal components without cracking or
breaking from the temperature. The motor must also resist the vibrations of its rotating
components inside, and the rigidity of the steel provides this feature.
[Source: Design Report 2]
 Chain – Steel
The chain is comprised of steel so that it can withstand the friction generated from
moving over the two sprockets and the tensioner, as well as the friction created between
its own components when in motion. Steel creates a rigid part that can be easily
reproduced through a stamping process and will not fail under the forces generated when
operating the scooter.
[Source: Design Report 2]
 Chain Tensioner – Magnesium Alloy
These parts are manufactured using a magnesium alloy. This metal was chosen for its
high strength to weight ratio and ease of machinability. Magnesium is the lightest
structural metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its
material properties give it a high damping ratio so that it reduces the vibrations
transferred to the hands and feet of the rider. In addition, magnesium has good fatigue
and dent resistance which allows the scooter parts to last longer without wearing out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Die Casting
 Chain Tensioner Spring – Steel
Steel was used for the spring for its ability to withstand repetitive motions without
breaking. It is also pliable when in wire form so it aids in the ability to form coils without
unwinding.
Fabrication Process: CNC Machine
 Clutch – Magnesium Alloy
These parts are manufactured using a magnesium alloy. This metal was chosen for its
high strength to weight ratio and ease of machinability. Magnesium is the lightest
structural metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its
Group 6 pg. 17

20. material properties give it a high damping ratio so that it reduces the vibrations
transferred to the hands and feet of the rider. In addition, magnesium has good fatigue
and dent resistance which allows the scooter parts to last longer without wearing out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Die Casting
 Sprocket – Magnesium Alloy
These parts are manufactured using a magnesium alloy. This metal was chosen for its
high strength to weight ratio and ease of machinability. Magnesium is the lightest
structural metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its
material properties give it a high damping ratio so that it reduces the vibrations
transferred to the hands and feet of the rider. In addition, magnesium has good fatigue
and dent resistance which allows the scooter parts to last longer without wearing out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Die Casting
Wheels:
 Tires – Synthetic Rubber Compound
The tire’s rubber material and pattern allow the tire to have a good grip with the surface it
is rotating about at both wet and dry conditions, in order to create the traction necessary.
The material of the tire is able to withstand both cold and hot temperatures while still
performing its function without cracking. The material of the tire helps in the longevity of
the tire since it can withstand thousands of revolutions and usage without breaking. The
tire material must be able to withstand deformations from the terrain and combined
weight of the rider and the scooter.
[Source: Design Report 2]
 Inner Tubes – Butyl Rubber
The inner tubes of the tire are manufactured from Butyl Rubber. This material has good
damping properties to help cut down on the vibrations generated while riding that could
transfer to the rest of the scooter. The material properties allow the tube to within stand
high pressure and have the ability to elastically deform without bursting. This material is
resistant to weathering when exposed to the environment. It also has quick curing times
to allow for lower manufacturing times.
[Source: http://www.exxonmobilchemical.com/Chem-English/brands/butyl-rubber-
exxon-butyl-rubber.aspx?ln=productsservices]
Group 6 pg. 18

21.  Rims - Polypropylene
Polypropylene (PP) is a highly versatile plastic with a fairly low density and low cost. PP
can be used in many molding and extrusion processes. It is flexible and impact resistant
so that it can withstand any bumps endured while riding the scooter. An added benefit is
that polypropylene can be dyed without degrading the integrity of the material.
[Source: http://composite.about.com/od/Plastics/a/What-Is-Polypropylene.htm]
Fabrication Process: Plastic Injection Molding
 Hubs – Magnesium Alloy
These parts are manufactured using a magnesium alloy. This metal was chosen for its
high strength to weight ratio and ease of machinability. Magnesium is the lightest
structural metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its
material properties give it a high damping ratio so that it reduces the vibrations
transferred to the hands and feet of the rider. In addition, magnesium has good fatigue
and dent resistance which allows the scooter parts to last longer without wearing out. The
magnesium hub can then form a tight seal with the bearings to prevent them from sliding
out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Die Casting
Battery Box – Polypropylene
Polypropylene (PP) is a highly versatile plastic with a fairly low density and low cost. PP
can be used in many molding and extrusion processes. It is flexible and impact resistant
so that it can withstand any bumps endured while riding the scooter. An added benefit is
that polypropylene can be dyed without degrading the integrity of the material.
[Source: http://composite.about.com/od/Plastics/a/What-Is-Polypropylene.htm]
Fabrication Process: Plastic Injection Molding
Brake:
 Brake Caliper – Magnesium Alloy
This part is manufactured using a magnesium alloy. This metal was chosen for its high
strength to weight ratio and ease of machinability. Magnesium is the lightest structural
metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its material
properties give it a high damping ratio so that it reduces the vibrations transferred to the
hands and feet of the rider. In addition, magnesium has good fatigue and dent resistance
which allows the scooter parts to last longer without wearing out. The magnesium hub
can then form a tight seal with the bearings to prevent them from sliding out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Die Casting
Group 6 pg. 19

22.  Brake Casing – Magnesium Alloy
This part is manufactured using a magnesium alloy. This metal was chosen for its high
strength to weight ratio and ease of machinability. Magnesium is the lightest structural
metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its material
properties give it a high damping ratio so that it reduces the vibrations transferred to the
hands and feet of the rider. In addition, magnesium has good fatigue and dent resistance
which allows the scooter parts to last longer without wearing out. The magnesium hub
can then form a tight seal with the bearings to prevent them from sliding out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Die Casting
 Brake Latch – Magnesium Alloy
This part is manufactured using a magnesium alloy. This metal was chosen for its high
strength to weight ratio and ease of machinability. Magnesium is the lightest structural
metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its material
properties give it a high damping ratio so that it reduces the vibrations transferred to the
hands and feet of the rider. In addition, magnesium has good fatigue and dent resistance
which allows the scooter parts to last longer without wearing out. The magnesium hub
can then form a tight seal with the bearings to prevent them from sliding out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm
Fabrication Process: Die Casting
 Brake Drum – Magnesium Alloy
This part is manufactured using a magnesium alloy. This metal was chosen for its high
strength to weight ratio and ease of machinability. Magnesium is the lightest structural
metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its material
properties give it a high damping ratio so that it reduces the vibrations transferred to the
hands and feet of the rider. In addition, magnesium has good fatigue and dent resistance
which allows the scooter parts to last longer without wearing out. The magnesium hub
can then form a tight seal with the bearings to prevent them from sliding out.
[Sources: http://www.azom.com/article.aspx?ArticleID=10415;
http://www.wellcharter.com/Magnesium/Mag_Adv.htm]
Fabrication Process: Die Casting
Washers/Spacers/Screws – Steel
Steel is used for this part to allow for a rigid component that can be easily replicated
through stamping and extrusion processes. Steel provides structural integrity without
adding a large amount of additional weight
[Source: Design Report 2]
Group 6 pg. 20

23. Fabrication Processes
Magnesium Alloy-
The material properties of magnesium makes it one of the easiest materials to manufacture. It
has the ability to be machined, molded, stamped, and extruded with a high production rate.
To prevent corrosion, magnesium is usually coated with paint.
 Die Cast- During the casting process, molten magnesium is drawn into the chamber and
through the nozzle into the mold. The molds, or dies, are composed of two halves that are
clamped together while the metal is being injected. Once cooled, the molds are separated
and ejector pins push the pieces out molds. One advantage to using magnesium in place
of aluminum during the die casting is its quick solidity rate. To clean up any rough edges
or polish the finish, the die casted part would be taken to a grinding wheel.
Hot Die Casting Process
Cold Die Casting Process
[Source: http://en.wikipedia.org/wiki/Die_casting]
 Extrusion-During the hot extrusion process, a large block of the metal is heated past is
recrystallization temperature. It is then pressed through a die that has been cut into the
desired shape.
[Source: http://en.wikipedia.org/wiki/Extrusion#Hot_extrusion]
TIG Welding- A tungsten rod is introduced inside a cloud of welding gas, which is typically
argon, to provide a current to ignite the gas. This heat creates a small area where the metal parts
begin to melt. To create the weld, a filler rod it pulled along the area to fix the two pieces
together. [Source: http://www.millerwelds.com/resources/tech_tips/TIG_tips/]
Tension Springs- Tension springs like the one used in the folding mechanism are manufactured
by CNC machines when ordered in large quantities. Steel wire cords, which vary in size, are fed
to the CNC machine that coils the wire into the required shape. Rollers of the CNC machines
force the steel wire through the coiling point where it gets the coiling done by a tool at the end
called the mandrel. Springs can be custom made into many different requirements and the
number of coils will be the dependent on the amount of wire that is fed through the coiling
machine. After they are coiled, springs get their ends shaped depending on the application in this
case hook ends. The spring is then tested and relieved of any bending stress that was
accumulated due to the coiling.
[Source: http://www.diamondwire.com/about-springs/spring-manufacturing-process.html]
Group 6 pg. 21

24. Torsional Springs- Torsion springs are manufactured by CNC machines when ordered in large
quantities. Steel wire cords, which vary in size, are fed to the CNC machine that coils the wire
into the required shape. Rollers of the CNC machines force the steel wire through the coiling
point where it gets the coiling done by a tool at the end called the mandrel. Springs can be
custom made into many different requirements and the number of coils will be the dependent on
the amount of wire that is fed through the coiling machine. After they are coiled, springs get their
ends shaped depending on the application. Torsional spring resist rotational forces and their ends
are shaped very specifically to their application.
[Source: http://www.diamondwire.com/about-springs/spring-manufacturing-process.html;
http://www.acewirespring.com/torsion-springs.html]
Plastic Injection Molding- Pellets of the desired plastic is added to the hopper of the machine,
they are feed into the extruder using a screw mechanism and heated along the way. The plastic is
injected into the molds and left to solidify. Once cooled, the molds are separated and ejector pins
push the part out of the mold (with any excess plastic removed later).
When manufacturing the wheels, the wheel hubs will be inserted into the molds before the
injection process to mate both parts.
[Source: Dr. Ifju, Lecture 18 10/15/2014]
Liquid Injection Molding - The desired liquid and its hardening catalyst are held in separate
tanks until production. The liquid and catalyst are then pumped through a measuring unit to
ensure the proper ratio. Once measured the components are combined in mixers and then
pumped into the molds.
[Source: http://www.thomasnet.com/articles/plastics-rubber/liquid-injection-molding]
Group 6 pg. 22

25. Assembly Process
Front Section Assembly
Step 1
Align the front frame section so that the folding mechanism arc is upwards and towards
the left hand side.
𝛼 = 360° 𝛽 = 360°
Step 2
Pick up the female revolving axis arm with the dominant hand and insert it into the lower
circular hole on the front frame section via the hole cut in the angle piece.
𝛼 = 360° 𝛽 = 0°
Step 3
Grab the fork holder and place in the arbor press.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 23

26. Step 4
Pick up the fork guide and insert it into the press with the smaller hole aligned with the
hole in the holder arm. Use the arbor press to press fit the fork guide to the holder arm.
𝛼 = 360° 𝛽 = 0°
Step 5
Flip the holder arm and place it back in the press.
𝛼 = 360° 𝛽 = 360°
Step 6
Pick up second fork guide and align the smaller hole with the other hole in the holder
arm. Use the arbor press to create a press fit between the fork guide and the holder arm.
𝛼 = 360° 𝛽 = 0°
Step 7
Pick up fork holder arm and locate with respect to the front frame section as shown in
following picture.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 24

27. Step 8
Pick up lock rod with the dominant hand and begin to insert it into the notch in the front
frame section and the holder arm.
𝛼 = 360° 𝛽 = 360°
Step 9
Using tweezers, pick up the folding mechanism spring and locate the spring such that the
top hook is concentric with the lock rod.
𝛼 = 180° 𝛽 = 180°
Step 10
Push lock rod through spring hook and out other end of the fork holder arm and the front
section frame.
𝛼 = 360° 𝛽 = 0°
Group 6 pg. 25

28. Step 11
Pick up the lock rod spacer with the dominant hand and insert it around the lock rod.
Repeat for the other side of the lock rod.
𝛼 = 180° 𝛽 = 0°
Step 12
Pick up the rod clip with the dominant hand and using force insert it onto the notch in the
lock rod. Repeat for the opposite side.
𝛼 = 180° 𝛽 = 0°
Step 13
Pick up the revolving axis spacer with the dominant hand and insert it around the female
revolving axis arm.
𝛼 = 180° 𝛽 = 0°
Group 6 pg. 26

29. Step 14
Align the fork holder arm with respect to the circular hole and the revolving axis arm and
insert the female revolving axis arm up to the notch in the end.
𝛼 = 360° 𝛽 = 0°
Step 15
Pick up the rod clip with the dominant hand and insert it on the notch at the end of the
female revolving axis arm.
𝛼 = 180° 𝛽 = 0°
Group 6 pg. 27

30. Step 16
Pick up the male revolving axis arm with the non-dominant hand and insert it into the
circular hole in the front frame section via the hole in the angled section.
𝛼 = 360° 𝛽 = 0°
Step 17
Using tweezers, pick up and locate the second spacer between the front frame section and
fork holder arm with respect to the male revolving axis arm and insert arm through
spacer.
𝛼 = 180° 𝛽 = 0°
Step 18
Using tweezers, ensure that the male end is inserted through the bottom hook of the
spring. Use Allen wrenches to fasten male and female revolving axis arms together.
𝛼 = 360° 𝛽 = 0°
Step 19
Pick up the rod clip with the dominant hand and insert it onto the notch at the end of the
male revolving axis arm.
𝛼 = 180° 𝛽 = 0°
Group 6 pg. 28

31. Fork Assembly
Step 20
Pick up the fork with the shaft end pointed upwards.
𝛼 = 180° 𝛽 = 360°
Step 21
Pick up front tire axle ring and insert it around the fork shaft and slide it down until it
rests on the shelf on the shaft of the fork.
𝛼 = 360° 𝛽 = 0°
Step 22
Pick up the bearing washer and locate it above the front tire axle ring on the shaft.
𝛼 = 360° 𝛽 = 0°
Group 6 pg. 29

32. Step 23
Insert the front fork assembly upwards into the fork holder arm and hold in place.
𝛼 = 360° 𝛽 = 0°
Step 24
Pick up and insert the second bearing washer onto the fork shaft.
𝛼 = 180° 𝛽 = 0°
Step 25
Pick up and insert the fork bar lower nut around the fork shaft. Screw on until it is
securely tightened.
𝛼 = 360° 𝛽 = 0°
Step 26
Pick up and locate the fork bar washer above the lower nut.
𝛼 = 180° 𝛽 = 0°
Group 6 pg. 30

33. Step 27
Pick up and insert the fork bar upper nut around the fork shaft and screw on until it is
securely tightened.
𝛼 = 360° 𝛽 = 0°
Front Axle Assembly
Step 28
Pick up front wheel hub and lay flat.
𝛼 = 180° 𝛽 = 0°
Step 29
Pick up bearing with dominant hand and align with hole in the wheel hub. Use a soft
hammer to press fit the bearing into the hole.
𝛼 = 180° 𝛽 = 0°
Group 6 pg. 31

34. Step 30
Pick up the inner rod bearing with the dominant hand and insert into the wheel hub.
𝛼 = 180° 𝛽 = 0°
Step 31
Pick up the second bearing the dominant hand and using a soft hammer, press fit onto
open end of the wheel hub.
𝛼 = 180° 𝛽 = 0°
Step 32
Pick up the tire tube and stretch around the hub, aligning the valve with the
corresponding hole in the hub.
𝛼 = 180° 𝛽 = 360°
Group 6 pg. 32

35. Step 33
Align the front wheel assembly with the axel holes in the front fork.
𝛼 = 180° 𝛽 = 0°
Step 34
Pick up the female socket drive post with the non-dominant hand and insert through the
holes in the fork and the front wheel assembly.
𝛼 = 360° 𝛽 = 0°
Group 6 pg. 33

36. Step 35
Pick up the male socket drive post with the dominant hand and insert through holes on
the other side of the front fork and front wheel assembly. Use two Allen keys to tighten
the socket posts.
𝛼 = 360° 𝛽 = 0°
Handlebar Assembly
Step 36
Pick up telescoping tube 1 with the non-dominant hand and position the end with only
one hole towards the dominant hand.
𝛼 = 360° 𝛽 = 0°
Step 37
Pick up the button connector with the dominant hand and align such that the button end is
away from the tube. Simultaneously compress the button connector while inserting it into
the tube, aligning the button and the hole. Repeat previous two steps for telescoping tubes
2-4.
𝛼 = 360° 𝛽 = 360°
Step 38
Pick up tube 1 with the non-dominant hand and tube 2 with the dominant hand. Compress
the button connector on tube 2 and slide it into tube 1 through the side with the button. If
assembling for riding, allow button connector to be inserted into one of the holes on the
top of tube 1. If assembling for travel, avoid the holes on top of tube 1 and slide tube 2
into tube 1 until tube 2 hits the connector within tube 1. Repeat this process with tubes 3
and 4 (3 into 2 and then 4 into 3).
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 34

37. Step 39
Pick up a single handlebar with the non-dominant hand and align so the hole in the bar is
towards the left and facing the holder.
𝛼 = 360° 𝛽 = 360°
Step 40
Pick up a button connector with the dominant hand. Compress and insert the button
connector, same as before, through the hole-end of the handlebar, allowing the button to
be housed in the hole.
𝛼 = 360° 𝛽 = 360°
Step 41
Pick up throttle twist holder with the dominant hand and slide onto the handle bar from
left to right.
𝛼 = 360° 𝛽 = 360°
Step 42
Pick up the throttle twist with the dominant hand and slide onto handle bare from left to
right and onto twist holder.
𝛼 = 360° 𝛽 = 360°
Step 43
Pick up the motor side grip with the dominant hand and slide onto the handle bar.
𝛼 = 360° 𝛽 = 0°
Step 44
Once the grip is in place and all other components are aligned, use a screwdriver to screw
the throttle twist holder in place.
Group 6 pg. 35

38. Step 45
Grab second handlebar with non-dominant hand and a button connector with the
dominant hand. Compress and insert the connector into the handlebar such that the button
is housed in hole. Align the button and hole on the right hand side facing the holder.
𝛼 = 360° 𝛽 = 360°
Step 46
Pick up the hand brake with the dominant hand and slide onto the handlebar such that the
brake is pointed to the left.
𝛼 = 360° 𝛽 = 360°
Step 47
Pick up brake side grip and slide onto the handlebar behind the brake.
𝛼 = 360° 𝛽 = 0°
Step 48
Once the brake and grip are in place and aligned properly, use a screwdriver to tighten
the brake in place.
Rear Axle Assembly
Step 49
Grab rear frame section and align with the deck down and the battery support rails further
away.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 36

39. Step 50
Pick up the motor the dominant hand and align the motor holes with holes in the rear
frame section as shown.
𝛼 = 360° 𝛽 = 360°
Step 51
Grab a motor mount screw with the non-dominant hand and insert through first the hole
in the frame section and then the corresponding motor hole.
𝛼 = 360° 𝛽 = 0°
Group 6 pg. 37

40. Step 52
Grab a motor mount nut and use wrenches to tighten onto the screw. Repeat last two
steps for the other motor hole.
𝛼 = 180° 𝛽 = 0°
Step 53
Pick up rear wheel hub and lay it flat.
𝛼 = 180° 𝛽 = 0°
Step 54
Pick up bearing with the dominant hand and press fit it into the rear wheel hub using a
soft hammer.
𝛼 = 180° 𝛽 = 0°
Group 6 pg. 38

41. Step 55
Pick up inner bearing rod with the dominant hand and insert it on other side of the rear
wheel hub.
𝛼 = 180° 𝛽 = 0°
Step 56
Pick up second bearing and press fit it onto open end of the hub using a soft hammer.
𝛼 = 180° 𝛽 = 0°
Step 57
Stretch the tube and tire around the rear wheel hub, aligning the valve with hole in the
hub.
𝛼 = 180° 𝛽 = 360°
Group 6 pg. 39

42. Step 58
Pick up the clutch with the dominant hand and screw onto one side of the hub.
𝛼 = 360° 𝛽 = 0°
Step 59
Pick up the brake drum with the dominant hand and screw onto other side of the hub with
the hollow end facing the tire.
𝛼 = 360° 𝛽 = 0°
Step 60
Pick up the rear axle with the dominant hand and through the hub.
𝛼 = 180° 𝛽 = 0°
Group 6 pg. 40

43. Step 61
Pick up the brake assembly with the dominant hand and slide over the brake drum.
𝛼 = 360° 𝛽 = 0°
Step 62
Pick up a washer and slide onto axle behind the brake assembly.
𝛼 = 180° 𝛽 = 0°
Step 63
Pick up the small spacer with the dominant hand and slide onto the clutch side of the
axle.
𝛼 = 180° 𝛽 = 0°
Step 64
Pick up the cut washer with the dominant hand and slide on the axle behind the spacer.
𝛼 = 180° 𝛽 = 0°
Group 6 pg. 41

44. Step 65
Pick up the chain with both hands and engage the links on one end to the clutch sprocket
and on the other end to the motor sprocket.
𝛼 = 180° 𝛽 = 0°
Step 66
Pick up the rear axle assembly and insert it on the rear wheel supports, aligning the clutch
sprocket with the motor sprocket.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 42

45. Step 67
Pick up the medium sized washer with the dominant hand and slide onto the axle.
𝛼 = 180° 𝛽 = 0°
Step 68
Pick up the split washer and slide onto the axle behind the medium sized washer.
𝛼 = 180° 𝛽 = 0°
Step 69
Pick up the rear axle nut and screw it on behind the split washer. Repeat the past three
steps for other side of the axle.
𝛼 = 360° 𝛽 = 0°
Step 70
Grab the chain tensioner spring and insert it around the chain tensioner and force spring
arm around the tensioner arm.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 43

46. Step 71
Pick up the tensioner and align the tensioner hole with the hole on the inside of the right
side rear wheel support.
𝛼 = 360° 𝛽 = 0°
Step 72
Pick up the tensioner screw with the dominant hand and insert through first the tensioner
and then the rear wheel support. While inserting screw make sure to align the spring
through small hole in rear wheel support.
𝛼 = 360° 𝛽 = 0°
Group 6 pg. 44

47. Step 73
Pick up the tensioner nut with the dominant hand and, using a wrench, tighten to the rear
wheel support.
𝛼 = 180° 𝛽 = 0°
Battery Box Assembly
Step 74
Align the battery tub with the base downwards and the rectangular on/off switch hole on
the front left hand side.
𝛼 = 360° 𝛽 = 360°
Step 75
Pick up the battery with the dominant hand and center it on the right hand side of the tub,
ensuring the base is down and connectors toward the left.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 45

48. Step 76
Pick up the on/off switch with the dominant hand. Using force, pop on the switch to the
rectangular hole in front left side of the tub such that the red switch is facing outwards
with the “ON” lettering on the top.
𝛼 = 360° 𝛽 = 360°
Step 77
Grab the reset button with the non-dominant hand and insert it from the inside of the tub
through the circular hole above and to the left of the on/off switch.
𝛼 = 360° 𝛽 = 0°
Step 78
Pick up the reset button nut in the dominant hand and screw onto the reset button from
the outside of the battery tub.
𝛼 = 360° 𝛽 = 0°
Group 6 pg. 46

49. Step 79
Grab the charger port with the non-dominant hand near the wires and the charger port cap
with the dominant hand. Push the end of the cover over the ridge of the charger port.
𝛼 = 360° 𝛽 = 0°
Step 80
Feed the wires from the charger port through the remaining hole next to the reset button
through the outside of the battery tub and insert the port into the hole.
𝛼 = 360° 𝛽 = 0°
Step 81
Pick up the charger port nut with the dominant hand and feed it over the wires of the
charger port and screw it onto the charger port, securing it to the battery tub.
𝛼 = 180° 𝛽 = 0°
Step 82
Pick up the processor with the dominant hand and align it with the screw hole to the left
of the battery box.
𝛼 = 360° 𝛽 = 180°
Group 6 pg. 47

50. Step 83
Grab one of the processor screws and align with the screw hole of the processor. Use a
screwdriver to tighten processor to battery tub. Repeat this step for the other processor
screw.
𝛼 = 360° 𝛽 = 0°
Step 84
Pick up the battery box and slide it into the battery impact cage, aligning the hole on the
top.
𝛼 = 360° 𝛽 = 180°
Group 6 pg. 48

51. Step 85
Pick up the entire battery box assembly and slide onto the support rails of the rear frame
assembly such that the battery is towards the wheel.
𝛼 = 360° 𝛽 = 360°
Step 86
Run the motor wire from the motor through the notch at the rear of the battery tub into
the tub.
𝛼 = 360° 𝛽 = 0°
Step 87
Hold the battery wire with the non-dominant hand and pick up the wire clip with the
dominant hand and insert the clip over the metal tabs
𝛼 = 360° 𝛽 = 180°
Step 88
Holding the brake line in the dominant hand, feed the line from the brake assembly
through the hole in the back of the tub.
𝛼 = 360° 𝛽 = 0°
Step 89
Following the wiring diagram, attach the three wires to the On/Off switch.
𝛼 = 360° 𝛽 = 360°
Step 90
Following the wiring diagram, attach the two wires to the charger port.
𝛼 = 360° 𝛽 = 360°
Step 91
Following the wiring diagram, attach the five wires to the processor.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 49

52. Step 92
Run brake and throttle cables through the largest hole of the battery tub cover.
𝛼 = 360° 𝛽 = 0°
Step 93
Pick up the battery tub cover and place on top of the battery box assembly such that the
large hole is towards the on/off switch side. Align the holes of the cover with the holes of
the cage, frame and tub.
𝛼 = 180° 𝛽 = 360°
Step 94
Pick up one of the battery box screws and screw down cover to the support rail and tub.
Repeat for the three other holes.
𝛼 = 360° 𝛽 = 0°
Group 6 pg. 50

53. Step 95
Run the brake line up the handlebars and insert the rounded tip into the slot on the
underside of the brake handle.
𝛼 = 360° 𝛽 = 180°
Step 96
Feed the brake line into the channel on the front of the brake handle and through the
metal screw attached to the hand brake.
𝛼 = 360° 𝛽 = 0°
Step 97
Grab the metal screw with the dominant hand and tighten to secure the brake line.
𝛼 = 360° 𝛽 = 0°
Group 6 pg. 51

54. Folding Deck Assembly
Step 98
Pick up one plastic hinge with the non-dominant hand and align with the holes on the top
of the folding deck with hinge side downwards.
𝛼 = 360° 𝛽 = 180°
Step 99
Pick up one of the hinge screws and secure the hinge to the deck top. Repeat for the other
hole in the hinge and then repeat past two steps for the second hinge.
𝛼 = 360° 𝛽 = 0°
Step 100
Align the remaining holes on the other side of the hinge with holes on the rear frame
assembly deck.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 52

55. Step 101
Pick up a hinge screw and secure the hinge to the rear frame assembly. Repeat for the
three remaining hinge holes. Then fold up the deck top.
𝛼 = 360° 𝛽 = 0°
Step 102
Pick up a silicon deck damper and adhere lengthwise to the underside of the folding deck
in between the hinge holes. Repeat for the other side of the deck.
𝛼 = 360° 𝛽 = 180°
Group 6 pg. 53

56. Frame Assembly
Step 103
Pick up the left frame rail and align such that the front is towards the left and holes are on
the closest side. The front is indicated by the letter “F” on the tip of the rail.
𝛼 = 360° 𝛽 = 360°
Step 104
Using the long tweezers apparatus, install the frame rail button connectors in the order
shown. The connector orientation flips 180 Degrees about the button on the connector for
locations 3 and 4. Repeat last two steps for right frame rail.
𝛼 = 360° 𝛽 = 360°
Step 105
Pick up the front section assembly with the non-dominant hand. With the dominant hand,
pick up the left frame rail and insert the front end of the rail through the square hole on
the left side of the front section assembly, ensuring the button connectors are facing
outward to line up with the holes in the front assembly. Repeat for the right frame rail.
Then using one hand on each frame rail, compress the first button connectors and slide
the frame rails into the front frame section, locking it into place with the button
connectors.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 54

57. Step 106
Pick up the rear frame section and align it with the frame rails. Slide the rear section onto
the frame rails, up to the closest set of button connectors. Then using one hand on each
frame rail, compress the first button connectors and slide the rear frame section onto the
frame rails.
𝛼 = 360° 𝛽 = 360°
Deck Locator Assembly
Step 107
Pick up the deck locator with the non-dominant hand and the deck locator silicon pad
with the dominant hand. Adhere the silicon pad to the underside the non-hole ledge.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 55

58. Step 108
Pick up the deck locator spacer with the dominant hand and align with the top hole in the
front deck assembly.
𝛼 = 180° 𝛽 = 0°
Step 109
Pick up the deck locator assembly and align the hole with the hole in the front deck
assembly with the silicon pad downwards.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 56

59. Step 110
Pick up the deck locator screw with the dominant hand and insert it into the hole of the
deck locator. Using a screwdriver, tighten down the locator such that it is not loose yet
still able to spin about the hole. Repeat past four steps for the deck locator on the other
side of the front deck assembly.
𝛼 = 360° 𝛽 = 0°
Chain Guard Assembly
Step 111
Grab the chain side guard and locate the screw holes with the holes on the right rear
wheel support.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 57

60. Step 112
Pick up one of the chain guard screws with the dominant hand and insert into the hole on
the chain guard. Securely tighten the screw with a screwdriver and repeat for the other
screw hole on the guard. Repeat last two steps for the brake side guard on the other side
of the scooter.
𝛼 = 360° 𝛽 = 0°
Final Scooter Assembly
Step 113
Pick up the handlebar assembly and align the telescoping tubes with the fork. Press the
bottom button connector and slide the handlebar assembly into the fork.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 58

61. Step 114
Pick up a frame end cap and align it with the hole in the frame rail. Using a slight
amount, locate the cap inside the frame rail in an interference fit. Repeat this for the three
remaining frame rail hole locations.
𝛼 = 360° 𝛽 = 360°
Group 6 pg. 59

62. Table 3: Handling and Insertion Times
Handling Insertion
Step Alpha Beta Alpha +
Beta
# of
Occurrences
Handling
Time
Step
Time
Source # of
Occurrences
Insertion
Time
Step
Time
Source
1 360 360 720 1 1.95 1.95 (3,0) - - - -
2 360 0 360 1 1.5 1.5 (1,0) 1 4 4 (0,1)
3 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)
4 360 0 360 1 1.5 1.5 (1,0) 1 3.5 3.5 (9,3)
5 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)
6 360 0 360 1 1.5 1.5 (1,0) 1 3.5 3.5 (9,3)
7 360 360 720 1 1.95 1.95 (3,0) 1 5.5 5.5 (0,6)
8 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)
9 180 180 360 1 4.75 4.75 (5,2) 1 6.5 6.5 (2,2)
10 360 0 360 1 1.5 1.5 (1,0) 1 5.5 5.5 (2,0)
11 180 0 180 2 1.43 2.86 (0,1) 2 1.5 3 (0,0)
12 180 0 180 2 1.69 3.38 (0,3) 2 5 10 (3,1)
13 180 0 180 1 1.43 1.43 (0,1) 1 4 4 (1,0)
14 360 0 360 1 1.5 1.5 (1,0) 1 1.5 1.5 (0,0)
15 180 0 180 1 1.69 1.69 (0,3) 1 5 5 (3,1)
16 360 0 360 1 1.5 1.5 (1,0) 1 4 4 (1,0)
17 180 0 180 1 6.85 6.85 (4,1) 1 4.5 4.5 (4,0)
18 360 0 360 1 5.6 5.6 (8,3) 1 10 10 (5,8)
19 180 0 180 1 1.69 1.69 (0,3) 1 5 5 (3,1)
20 360 0 360 1 1.5 1.5 (1,0) - - - -
21 360 0 360 1 1.5 1.5 (1,0) 1 1.5 1.5 (0,0)
22 360 0 360 1 1.5 1.5 (1,0) 1 1.5 1.5 (0,0)
23 360 0 360 1 3 3 (9,1) 1 5.5 5.5 (0,6)
24 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)
25 360 0 360 1 1.5 1.5 (1,0) 1 6 6 (3,8)
26 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)
27 360 0 360 1 1.5 1.5 (1,0) 1 6 6 (3,8)
28 180 0 180 1 1.13 1.13 (0,0) - - - -
29 360 0 360 1 1.5 1.5 (1,0) 1 7 7 (3,5)
30 180 0 180 1 1.13 1.13 (0,0) 1 5.5 5.5 (0,6)
31 180 0 180 1 1.13 1.13 (0,0) 1 7 7 (3,5)
32 180 360 540 1 1.8 1.8 (2,0) 1 8.5 8.5 (4,4)
33 180 0 180 1 1.13 1.13 (0,0) 1 5.5 5.5 (0,6)
34 360 0 360 1 1.5 1.5 (1,0) 1 5.5 5.5 (0,6)
35 360 0 360 1 1.5 1.5 (1,0) 1 6 6 (3,8)
36 360 0 360 4 1.5 6 (1,0) - - - -
Group 6 pg. 60

63. 37 360 360 720 4 1.95 7.8 (3,0) 4 4.5 18 (4,0)
38 360 360 720 3 1.95 5.85 (3,0) 3 4.5 13.5 (4,0)
39 360 360 720 1 1.95 1.95 (3,0) - - - -
40 360 360 720 1 1.95 1.95 (3,0) 1 4.5 4.5 (4,0)
41 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)
42 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)
43 360 0 360 1 1.5 1.5 (1,0) 1 2 2 (3,0)
44 - - - - - - - 1 6 6 (3,8)
45 360 360 720 1 1.95 1.95 (3,0) 1 4.5 4.5 (4,0)
46 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)
47 360 0 360 1 1.5 1.5 (1,0) 1 2 2 (3,0)
48 - - - - - - - 1 6 6 (3,8)
49 360 360 720 1 1.95 1.95 (3,0) - - - -
50 360 360 720 1 1.95 1.95 (3,0) 2 8 16 (1,6)
51 360 0 360 2 1.5 3 (1,0) 2 8 16 (1,6)
52 180 0 180 2 1.13 2.26 (0,0) 2 12 24 (5,9)
53 180 0 180 1 1.13 1.13 (0,0) - - - -
54 180 0 180 1 1.13 1.13 (0,0) 1 5 5 (3,1)
55 180 0 180 1 1.13 1.13 (0,0) 1 5.5 5.5 (0,6)
56 180 0 180 1 1.13 1.13 (0,0) 1 5 5 (3,1)
57 180 360 540 1 1.8 1.8 (2,0) 1 6 6 (3,4)
58 360 0 360 1 1.5 1.5 (1,0) 1 8 8 (3,9)
59 360 0 360 1 1.5 1.5 (1,0) 1 8 8 (3,9)
60 180 0 180 1 1.13 1.13 (0,0) 1 5.5 5.5 (0,6)
61 360 0 360 1 1.5 1.5 (1,0) 1 5.5 5.5 (0,6)
62 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)
63 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)
64 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)
65 180 0 180 1 4.1 4.1 (8,0) 1 9 9 (1,8)
66 360 360 720 1 3 3 (9,1) 1 1.5 1.5 (0,0)
67 180 0 180 2 1.13 2.26 (0,0) 2 1.5 3 (0,0)
68 180 0 180 2 1.13 2.26 (0,0) 2 1.5 3 (0,0)
69 360 0 360 2 1.5 3 (1,0) 2 6 12 (3,8)
70 360 360 720 1 1.95 1.95 (3,0) 1 5 5 (3,1)
71 360 360 720 1 1.95 1.95 (3,0) 1 9.5 9.5 (2,6)
72 360 0 360 1 1.5 1.5 (1,0) 1 9.5 9.5 (2,6)
73 180 0 180 1 1.13 1.13 (0,0) 1 8 8 (3,9)
74 360 360 720 1 1.95 1.95 (3,0) - - - -
75 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)
76 360 360 720 1 1.95 1.95 (3,0) 1 5 5 (3,1)
77 360 0 360 1 1.5 1.5 (1,0) 1 5.5 5.5 (0,5)
Group 6 pg. 61

64. 78 360 0 360 1 1.5 1.5 (1,0) 1 6 6 (3,8)
79 360 0 360 1 1.5 1.5 (1,0) 1 2 2 (3,0)
80 360 0 360 1 1.5 1.5 (1,0) 1 1.5 1.5 (0,0)
81 180 0 180 1 1.13 1.13 (0,0) 1 6 6 (3,8)
82 360 180 540 1 1.8 1.8 (2,0) 1 2.5 2.5 (0,2)
83 360 0 360 2 1.5 3 (1,0) 2 6 12 (3,8)
84 360 180 540 1 3 3 (9,1) 1 2.5 2.5 (0,2)
85 360 360 720 1 1.95 1.95 (3,0) 1 2.5 2.5 (0,1)
86 360 0 360 1 1.5 1.5 (1,0) 1 9 9 (9,8)
87 360 180 540 1 1.8 1.8 (2,0) 1 2 2 (3,0)
88 360 0 360 1 1.5 1.5 (1,0) 1 9 9 (9,8)
89 360 360 720 3 1.95 5.85 (3,0) 3 9 27 (9,8)
90 360 360 720 2 1.95 3.9 (3,0) 2 9 18 (9,8)
91 360 360 720 5 1.95 9.75 (3,0) 5 9 45 (9,8)
92 360 0 360 2 1.5 3 (1,0) 2 1.5 3 (0,0)
93 180 360 540 1 1.8 1.8 (2,0) 1 2.5 2.5 (0,2)
94 360 0 360 4 1.5 6 (1,0) 4 6 24 (3,8)
95 360 180 540 1 1.8 1.8 (2,0) 1 9 9 (9,8)
96 360 0 360 1 1.5 1.5 (1,0) 1 9 9 (9,8)
97 360 0 360 1 1.8 1.8 (1,1) 1 6 6 (3,8)
98 360 180 540 2 1.8 3.6 (2,0) 2 2.5 5 (0,2)
99 360 0 360 4 1.5 6 (1,0) 4 6 24 (3,8)
100 360 360 720 1 1.95 1.95 (3,0) 1 6.5 6.5 (0,8)
101 360 0 360 4 1.5 6 (1,0) 4 6 24 (3,8)
102 360 180 540 2 1.8 3.6 (2,0) 2 5 10 (3,1)
103 360 360 720 2 1.95 3.9 (3,0) - - - -
104 360 360 720 8 1.95 15.6 (3,0) 8 6 48 (5,0)
105 360 360 720 2 3 6 (9,1) 2 2 4 (3,0)
106 360 360 720 1 3 3 (9,3) 1 5 5 (3,1)
107 360 360 720 2 1.95 3.9 (3,0) 2 5 10 (3,1)
108 180 0 180 2 2.18 4.36 (0,4) 2 1.5 3 (0,0)
109 360 360 720 2 1.95 3.9 (3,0) 2 1.5 3 (0,0)
110 360 0 360 2 1.5 3 (1,0) 2 6 12 (3,8)
111 360 360 720 2 1.95 3.9 (3,0) 2 5.5 11 (0,6)
112 360 0 360 4 1.5 6 (1,0) 4 6 24 (3,8)
113 360 360 720 1 1.95 1.95 (3,0) 1 2 2 (3,0)
114 360 180 540 4 1.8 7.2 (2,0) 4 2 8 (3,0)
Total Times: 296.55 789
Total Assembly Time: 1085.55 sec = 18.09 mins
Group 6 pg. 62

65. Performance Analysis
The Electric Slide scooter boasts some of the highest performance ratings to any
scooter on the market. Despite being lightweight, this scooter has the strength and torque
to operate under any urban conditions. The Electric Slide scooter was designed using the
E-300 Razor scooter as a base jumping-off point and so is designed to be better in every
physical category. This analysis will break down the calculations for the velocity, torque,
battery life, and turning radius and compare them to the E-300 Razor to outline
performance improvements.
Motor: Torque
The Electric Slide was designed to be faster and more powerful than the E-300
while only being half the weight. To do this, the design called for a much more powerful
motor. The motor is a 24 V electric motor rated for 750 W and 2600 RPM so that our
scooter can double the torque of the E-300 while not sacrificing speed.
According to the stall torque calculations provided by Dr. Ifju, the E-300 provides
an estimated stall torque of 11.43 Nm, providing a stall force of 90 N. The goal of our
design is to double this stall force, meaning our motor must provide at least 180 N of
force on the ground.
To calculate the rated torque for the motor we use the relation,

T 
P
n
where T is the torque, P is the power in watts, and n is the number of revolutions per
minute of the motor sprocket. Using a conversion factor to change the units to Nm, we
calculate the rated torque of our motor to be,

750
2600






30






2.75Nm
However, when we calculate the motor torque, we must take the battery into
consideration. Our battery is a Lithium Polymer 22.2 V battery pack with a 22 Ah
capacity. Because our motor’s rated power and RPM is at 24 V and our battery supplies
22.2 V, our motor’s power and torque will be lower than rated. The drop in torque that
the motor will experience is proportional to the drop in voltage. Therefore we can
calculate a more accurate torque output based on our battery.
 
2.7 5
2 2.2
2 4
 
 
 
 
 
  2.5 5Nm
Group 6 pg. 63

66. The torque now on the rear tire will be the calculated motor torque multiplied by
the gear ratio. Our motor sprocket has 11 teeth and our drive train sprocket has 30 teeth.
So our rear wheel torque will be,

2.55
30
11
 
 
 
 
 
 6.95Nm
Based on the stall torque calculations released by Dr. Ifju, the stall torque is a
little over two times the rated torque and in the calculations a factor of 2.3 was used. So
the stall torque of the tire for our motor and battery will be 6.95*2.3 = 15.98 Nm. Finally,
the stall force the tire provides can be calculated by

Fs t al l
Ts t al l
r
where r is the radius of the rear tire in meters. Our rear tire is 6 inches in diameter, or a
0.0762 meter radius. Therefore the stall force of our tire is

15.98
0.0762
209.75Nm
The E-300 Razor scooter provides 90 N of force on the ground. Our design
provides almost 210 N of force, more than 230% of the E-300 stall force. This increased
force also allows us to handle steeper terrain. To get an idea of the kind of slope our
scooter torque could handle, we can relate the slope of the incline the scooter would stall
at with riders of varying weight. Using a free-body diagram of the rear wheel, can make
the relation,

Fs t a l lW gs i n ()
where F is the force required prevent our scooter of a combined rider and scooter weight,
W, on a incline of slope,

, from rolling down the incline. We know our maximum stall
force is 209.75 Nm, so the incline a rider of given weight would stall at can be calculated
by arranging the equation like below. The data for a range of rider weights is also shown
on the next page.

si n1 209.75
W9.81






Group 6 pg. 64

67. Fig. 1: The graph shows the incline slopes that a rider between 100 lb – 220 lb could climb before stalling.
The equations used assume a relatively smooth, uniform surface.
The graph shows that with our given motor, someone weighing as much as 220 lbs could
climb an incline of up to 11 degrees before stalling. This means our scooter could be used
by riders in a wide range of areas, including areas with hills or steep inclines.
Motor: Speed
The second rating of performance is the scooter speed. Despite the design
requirement of the Electric Slide scooter to be half the weight of the E-300 Razor, we
needed a motor that could provide at least double the stall force without sacrificing speed.
The E-300 has a top speed of 15 mph. The speed of the scooter is dependant on the RPM
of the motor, the gear ratio of the drive train, and the size of the tire. The calculations in
this section will show that our design is faster than E-300 Razor scooter based on the
motor and battery chosen for our design.
As mentioned in the previous section, our battery is 22.2 V, less than the voltage
used for the rated power and RPM: 24 V. Just like the torque, the difference in RPM
between the motor at a lower voltage and the rated voltage is proportional to the
difference in voltage. Therefore, we can find the RPM our motor will run at with our
battery by multiplying it by the voltage ratio,

2600r a t e d
22.2
24
 
 
 
 
 
 2405RPM
Group 6 pg. 65

68. As the rotational motion is transmitted from the motor to the rear axle, the RPM
will be reduced by the gear ratio. Knowing that, the rotational speed of the back tire can
be calculated.
 
2 4 0 5
1 1
3 0
 
 
 
 
 
  8 8 1.8 3RPM
Then, using 6 inches as tire diameter, 881.83 RPM as the rotational speed, and
multiplying by a conversion factor to convert from inches per minute to miles per hour
(9.47x10-4
), we find that the velocity of the scooter to be
 
8 8 1.8 369.4 71 04
 1 5.7 4mph
Therefore, our motor, battery, and sprocket combination produces a scooter with a
speed 105% of the E-300 Razor, meeting our velocity specifications.
Battery Life
Another important performance factor is the battery life. The E-300 had an
effective battery life of 40 minutes. Our design must be as good or better than the E-300’s
battery performance. Our motor is much more powerful than the E-300’s motor and
therefore also draws more current, requiring a much more efficient battery in order to
provide the voltage for an adequate amount of time without being too large or heavy. Our
battery, a lithium polymer battery, provides 22.2 V with a 22 Ah capacity. In order to
calculate the battery life, we must find the current usage of our motor. Since power is a
function of current and voltage, the current of the motor can be determined by the
equation,

I 
P
V
The power of our motor with reduced battery voltage can be found by using the
power-voltage-resistance relation,

P 
V2
R






Using this relation, assuming a minimal change in resistance for the motor we can
calculate the new motor power knowing the actual voltage provided by the battery is
92.5% of the rated voltage.
 
Pa c t u a l
Va c t u a l
2
R

0.9 2 5Vr a t e d 
2
R
 0.8 5 6
Vr a t e d
2
R
 0.8 5 6Pr a t e d
Group 6 pg. 66

69. So the power of our motor coupled with our battery is,

Pa c t u a l0.856Pr a t e d0.856750641.72W
Now using this calculated power with the battery’s voltage into the current
equation above, we find the motor’s current usage to be,
 
I 
P
V

6 4 1.7 2
2 2.2
2 8.9 1A
Finally, if we divide the battery capacity by the current usage of the motor, we
find the battery life at that current. In this case, with our motor, and a capacity of 22 Ah,
our battery will have an effective life of

2 2
2 8.9 1
0.7 6hrs

45mins
Therefore, with our given power and electric needs, the Electric Slide scooter will
have an effective battery life of 45 minutes, a battery life 14% longer than the life of the
E-300 Razor scooter.
Turning Radius
The final performance factor is the turning radius, which dictates the rider’s
ability to make turns at varying speeds. A theoretical turning radius can be determined
from the equation below, where the angle is defined as the maximum angle of turning
allowed by the scooter, measured with respect to the straight forward position.
Turning Radius =Scooter Wheelbase


1
sin(angle)







The wheelbase of the scooter was determined to be 2.597 feet and a safe turning
radius of 50 degrees. These measurements result in the following calculation:
Scooter Turning Radius =

2.597
sin(50)
 3.39 (ft)
If a turning circle were desired, the turning ratio could be multiplied by two to
obtain a turning circle of diameter 6.78 feet. The turning radius for the Electric Slide
scooter is for a safe turning angle: 50. Since there is no limiting mechanism, the scooter
could turn sharper at slower speeds.
Group 6 pg. 67

70. Summary
Overall, using the E-300 Razor scooter as a launching point, our scooter shows an
improvement in every performance category, including over twice the E-300’s stall force.
The Electric Slide’s performance calculations, along with its strong, lightweight, and
compactable design show that this scooter will have a large desirability among other
products. The table below summarizes the performance specifications of the Electric
Slide and E-300 Razor scooter.
Table 4: Electric Slide and E-300 Razor performance specifications.
Electric Slide E-300 Razor Performance
Comparison
Stall Force (N) 209.75 90 233%
Speed (mph) 15.75 15 105%
Battery Life (mins) 45.66 40 114%
Wheelbase (ft) 2.60 2.50 104%
Group 6 pg. 68

71. Mechanical Analysis
Frame Loading Analysis
To ensure there would not be any failure in the structural elements of the design, a finite element
analysis was run using SolidWorks to determine the maxium deflection and von Mises stresses
on the base of the frame. A fine mesh (76,549 nodes) of the element was generated and a
simulation was run using normal loading conditions, having a 220 lb person standing on the
deck. Under these loading conditions the maximum deflection reached 0.0099 inches at the
center of the scooters deck and a von Mises stress of 3,410 psi (location is denoted with a red
circle). Using the equation below, it was determined that our frame has a factor of safety of 4.46
for a normal loading condition.
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 =
𝜎 𝑦𝑖𝑒𝑙𝑑
𝜎 𝑑𝑒𝑠𝑖𝑔𝑛
=
15,200 𝑝𝑠𝑖
3,410 𝑝𝑠𝑖
= 4.46
Group 6 pg. 69

72. A second simulation was run for an extreme condition with a rider of 500 lbs. This produced
resuts of a maximum deflection of 0.022 inches and a maximum von Mises stresses of 7,700 psi.
These maximums were located in the same positions of the scooter`s frame as for the original
loading condition. Using the equation below, this loading conditions gives a factor of safety of
1.97.
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 =
𝜎 𝑦𝑖𝑒𝑙𝑑
𝜎 𝑑𝑒𝑠𝑖𝑔𝑛
=
15,200 𝑝𝑠𝑖
7,700 𝑝𝑠𝑖
= 1.97
Group 6 pg. 70

73. Handlebars Loading Analysis
A loading analysis was simulated to determine whether the handle bars would buckle if 50
pounds of force were applied to the edges. A fine mesh (63,424 nodes) was generated and a
simulation was run to mimic an extreme case where force was only applied to the far ends of the
handlebar grips. Under this loading condition, the maximum deflection is 0.065 in and maximum
von Mises stress of 7,794 psi giving a factor of safety of 2.
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 =
𝜎 𝑦𝑖𝑒𝑙𝑑
𝜎 𝑑𝑒𝑠𝑖𝑔𝑛
=
15,200 𝑝𝑠𝑖
7,794 𝑝𝑠𝑖
= 1.95
Group 6 pg. 71

74. A loading analysis was simulated to determine whether the handle bars would buckle if 50
pounds of force were applied if someone were to pull back or push against the handlebars. A fine
mesh (63,316 nodes) was generated and a simulation was run to determine the maximum
deflection and von Mises stress. Under this loading condition, the maximum deflection is 0.31 in
and maximum von Mises stress of 8,098 psi giving a factor of safety of 2.
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 =
𝜎 𝑦𝑖𝑒𝑙𝑑
𝜎 𝑑𝑒𝑠𝑖𝑔𝑛
=
15,200 𝑝𝑠𝑖
8,098 𝑝𝑠𝑖
= 1.88
Group 6 pg. 72

75. Fork Loading Analysis
A loading analysis was done to simulate a 220 pound rider placing all of their weight directly on
the fork of the scooter. A fine mesh (55, 258 nodes) was generated and a simulation was run to
determine the maximum deflection and von Mises stress. Under these loading conditions, it was
found that the maximum deflection was 0.0015 in and the von Mises stress was 4,188 psi giving
us a factor of safety of 3.6.
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 =
𝜎 𝑦𝑖𝑒𝑙𝑑
𝜎 𝑑𝑒𝑠𝑖𝑔𝑛
=
15,200 𝑝𝑠𝑖
4,188 𝑝𝑠𝑖
= 3.6
Group 6 pg. 73

76. Group 6 pg. 74

77. Another simulation was run for the front fork to analysis what would happen during a front
impact of 100 pounds. A fine mesh (50,746 nodes) was generated and a simulation was run to
determine the maximum deflection and von Mises stress. Under these loading conditions, the
maximum deflection was found to be 0.0024 in and the maximum von Mises stress was 5,200 psi
giving a factor of safety of 3.
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 =
𝜎 𝑦𝑖𝑒𝑙𝑑
𝜎 𝑑𝑒𝑠𝑖𝑔𝑛
=
15,200 𝑝𝑠𝑖
5,200 𝑝𝑠𝑖
= 2.9
Group 6 pg. 75

78. Group 6 pg. 76

79. Chain Drive Assembly
In order for the scooter to be driven, electrical power from the battery must be converted
into mechanical power. This manipulation of energy takes place inside of the electric motor of
the scooter. Magnets are installed inside the housing of the motor in order to create a magnetic
field. Coils placed inside the motor carry an electric current from the battery source with a
component called the commutator attached to the end of these coils. The purpose of the
commutator is that it continuously reverses the electric current in the coils. Electric power is fed
into the commutator through objects called brushes, which come in “brush” with the
commutator. The alternating electric field created in the coils is then continually propelled to
rotate in the presence of the static magnetic field from the batteries. Figure 2 shows a simple
schematic of how this all works.
Fig. 2 – Simplified diagram of how an electric motor functions. Notice how the commutator allows for the current
from the battery to continually be reversed in the coil.
The motion created by the rotating coils is then used to rotate the driveshaft. At the end of
the drive shaft is a toothed gear called a sprocket. The sprocket is designed to have its teeth on
the outer edge to correlate with the spacing of the links of a roller chain. The sprocket on the
motor is quite small with only ten teeth. One end of the roller chain is wrapped around the motor
sprocket while the other end is attached to the wheel sprocket. The chain is comprised of two
distinct pieces, an inner and outer link. There are 32 of each, alternating and connect at their
respective ends by small pins. The chain used in this scooter assembly was a standard #25 roller
chain.
The sprocket that is connected the wheel is a much larger sprocket than the one of the
motor, containing 30 teeth. Holes are placed in this sprocket to allow it to be attached to the
clutch and wheel mount. As torque from the motor is created, the motor sprocket uniformly pulls
on the links of the chain. This rotation is translated across the whole length of the chain back to
the larger sprocket. The larger sprocket is consequently made to rotate as well spinning the tire in
the desired direction. This is what allows for propulsion of the tire and the scooter to be driven.
An additional part is added to this assembly to increase the overall effectiveness. The
chain tensioner is a piece that, as the name implies, creates tension on the underside of the roller
chain. A spring runs from a small hole in the frame to the chain tensioner. This forces the
Group 6 pg. 77

80. spinning roller of the tensioner to press against the bottom of the chain near the wheel sprocket.
This keeps the chain tight so that no links will slip off either of the sprocket teeth. [Design
Report 2]
Brake Assembly
During the operation of the scooter it is important for the rider to have an efficient and
safe means of stopping. The brake assembly works in tandem with the brake cable and the brake
drum on the rear axle to stop the scooter. The brake cable is connected to a latch, which is fixed
to the frame of the brakes, or the brake casing. The latch is also connected to a flexible metal
strip that can bend significantly without plastic deformation. A ceramic pad is screwed to the
metal strip and the other side of the metal strip is fixed to the brake casing. As the brake cable is
pulled it rotates the latch, which then contracts the brake caliper. The brake caliper contracts
until it contacts the brake drum attached to the rear axle. The brake caliper turns the rotational
energy of the rear axle into thermal energy through friction and the rear axle comes to a stop.
The brake cable is attached to the latch by a screw with a hole near the head. The screw
passes through a hole in the latch arm and, when tightened, pins the cable against the latch arm.
When the brake cable is pulled, it will pull on the end of the latch arm. Since the latch arm is
fixed at its vertex, this will cause a torque equal to the linear force applied by the brake cable
multiplied by the length of the latch arm. This rotational force will cause both arms to rotate in
the direction of the cable. This movement is diagramed in Fig. 3.
Fig. 3 – The brake cable provides a linear force on the latch arm (shown in red) that causes a rotational force (shown
in green) about the center of the latch. This will cause the other arm to rotate and pull on the end of the brake
caliper.
Group 6 pg. 78

81. The other arm of the latch will then rotate in the same direction as the force of the brake
cable, pulling on the end of the brake caliper. Since the brake caliper is attached to the brake
casing at the other end, the brake caliper will contract into a smaller diameter until it contacts the
brake drum.
Fig. 4 – The photo shows the motion of the latch and the caliper when the upper latch arm is pulled to the left. The
other latch arm rotates and pulls the brake caliper in creating a smaller diameter.
The brake caliper will cause a frictional force on the brake drum and will absorb the
rotational motion as heat. The brake drum is attached to the rear axle and the friction applied to
the brake drum will also stop the rotation of the rear axle, stopping the motion of the scooter.
However, once the brake cable is released, the brake caliper must return to its original
position to release the brakes. Since the brake cable can only act by pulling on the latch, the latch
will not automatically rotate back to reset the brake caliper once the brake cable is released.
Therefore, to return the latch and the brake caliper back to their original positions, a torsional
spring is hooked onto the latch arm and rests against the brake casing. The torsional spring acts
against the brake cable. As the brake cable rotates the latch arm (counter-clockwise at this view)
the torsional spring is compressed and creates an opposing force to rotate the latch back
(clockwise) to the original position. When the brake cable is pulled it overpowers the torsional
spring but when it is released the torsional spring acts to reverse the motion. Fig. 5 shows the
unobstructed view of the torsional spring and the rotation force it provides on the latch.
Group 6 pg. 79

82. Fig. 5 – The torsional spring has one coil, the diameter of which is concentric with the hole on in the latch
vertex. One arm rests against the wall of the brake casing, the other hooks around the latch arm to pull it in the
direction shown in blue.
Once the brake cable is released, the force of the torsional spring will pull the latch arm
to rotate in the direction shown in blue in Fig. 5. The torsional spring will return the latch to its
original position and the latch arm will allow the brake caliper to unbend back to its original
position, thereby releasing the brakes. In conclusion, using the brake cable and the torsional
spring to control the rotation of the latch, the brake cable can control the contraction of the brake
caliper and by relation, the frictional force applied to the brakes. [Source: Design Report 2]
Group 6 pg. 80

83. Thermal Analysis
During an analysis of our motor it is also important to estimate the losses that
occur. The most significant loss that occurs in the motor is loss due to heat. The
calculations performed in this analysis are for a motor operating freely under no load.
As mentioned before, the main loss in power is going to be through heat loss. The
other losses are small and can be ignored for this estimation. Using an energy balance of
the power of the motor, with the sum of the powers equaling zero, we can find the heat
loss in relation to the input and output power of the motor.

P  0  Pin  Pout  Ploss

Ploss  Pin  Pout
Then we can also relate the input and output for the motors to the motor
efficiency. We define the motor efficiency as the ratio of power gained as the power input
into the system. With that definition we can relate the power lost to the performance
efficiency.

 
Pout
Pin


Pin 
Pout


Ploss 
Pout

 Pout

Ploss  Pout
1

1






The efficiency was determined from a data set of standard average motor
efficiencies for motors of certain sizes. The data was fit with a linear regression line and
the line equation used to determine the efficiency for a motor at the same power usage at
which our motor runs. The fitted curve is shown in the graph below.
Group 6 pg. 81

84. Fig. 6 – The curve fit for the data uses a logarithmic approximation. The initial increase in motor sizes
results in a large jump in power efficiency.
Our motor runs at about 640 watts, or 0.86 horsepower. From the logarithmic fit,
our motor has an efficiency of about 77.7%. This efficiency represents the performance
of motor under no load. When a load is applied the motor efficiency will become lower
and the heat losses greater. Finally, plugging in the efficiency and using 640 watts as the
power out, we can estimate the thermal power loss.

Ploss  640
1
.777
1





180.26
Therefore, about 180 watts are lost due to heat during operation of the motor. The
heat loss accounts for approximately 22% of the power put into the system.
Group 6 pg. 82

85. Electrical and Control Analysis
The Charging Process
When the scooter is plugged in, the charging cord converts the 120 volts from the wall into the
22.2 volts of the battery. The charge travels through the charging port and into the controller
which than routes the charge into the batteries for storage. [Source: Design Report 2]
Operating the Scooter
To operate the scooter, the ON/OFF switch is moved to the ON position to close the circuit.
Once the circuit is closed, the throttle is twisted which sends a signal to the controller that pulls
power from the battery and sends it to the motor with uses the voltage to spin and rotate the
motor. This throttle is a proportional control, which means that speed the motor rotates is
proportionally dependent on the amount that the throttle is twisted. Due to the use of a LiPo
battery a low voltage indicator was added to the electrical circuit to alert the user when the
battery reaches 3V.
Group 6 pg. 83

86. Standard Parts List
Table 5: Off the Shelf Parts
Part Name Source Part
Number
Quantity Weight Total
750W Motor Electric
Parts
1 6.5 6.5
6S LiPo Battery 1 5.6 5.6
Tension Spring MC 9044K203 1 0.00145 0.00145
Fork Guide Old Sc 2 0.0254 0.0508
Bearing Washer Old Sc 2 0.01 0.02
Axle Ring Old Sc 1 0.03 0.03
Fork Bar Lower Nut Old Sc 1 0.0353 0.0353
Fork Bar Washer Old Sc 1 0.00372 0.00372
Fork Bar Top Nut Old Sc 1 0.02 0.02
Wheel Ball Bearing Old Sc 4 0.0272 0.1088
Socket Drive Post Set MC 97851A204 1 0.06 0.06
Button Connector Handle MC 92988A510 6 0.01 0.06
Motor Twist Holder Electric
Parts
1 0.14 0.14
Motor Twist Electric
Parts
1 0.02 0.02
Right Grip Electric
Parts
1 0.0795 0.0795
Left Grip Electric
Parts
1 0.13 0.13
Brake Handle Electric
Parts
1 0.3 0.3
Button Connector Rails MC 92988A530 8 0.0158 0.1264
End Nut MC 93827A245 2 0.0452 0.0904
Thin Washer MC 93286A029 1 0.00145 0.00145
Rear Axle MC 23595T16 1 0.06 0.06
Medium Rear Washer MC 93286A031 2 0.00266 0.00532
Split Luck Washer MC 92147A030 2 0.00507 0.01014
Tensioner Nut MC 90591A151 1 0.00115 0.00115
Motor Mount Screw MC 91280A421 2 0.0273 0.0546
Motor Mount Nut MC 90591A154 2 0.00657 0.01314
Processor Old Sc 1 0.157 0.157
Low Voltage Processor Quadcopter 1 0.05 0.05
ON/OFF Button Electric
Parts
1 0.00821 0.00821
Reset Button Electric
Parts
1 0.02 0.02
Reset Button Nut MC 93827A245 1 0.0011 0.0011
Battery Plug Electric
Parts
1 0.01 0.01
Group 6 pg. 84

87. Battery Plug Cap Electric
Parts
1 0.00418 0.00418
Battery Plug Nut MC 93827A241 1 0.00187 0.00187
Processor Screw MC 92005A220 2 0.00339 0.00678
Battery Box Screw MC 92005A222 8 0.00372 0.02976
Deck Hinge MC 1637A713 2 0.00392 0.00784
Deck Hinge Screw MC 91420A112 8 0.000515 0.00412
Brake Locator Screw MC 94792A424 1 0.002 0.002
Folding Deck Locator Screw MC 91735A013 2 0.00271 0.00542
Old Sc: Part used from Razor E300 scooter
MC: McMaster Carr
Electric Parts: Electric Scooter Parts.com
Quadcopter: Quadcopter.com
Group 6 pg. 85

88. Custom Parts List
Table 6: Custom Parts List
Part Name Quantity Weight Total
Frame Rail 2 0.69 1.38
Frame Front Section 2 0.11 0.22
Frame Rear Section 2 0.53 1.06
Deck Plate 2 0.67 1.34
Arc 2 0.05 0.1
Revolving Axis Arm Male 1 0.006 0.006
Revolving Axis Arm Female 1 0.004 0.004
Clip 4 0.000044 0.000176
Lock Rod 1 0.01 0.01
Lock Rod Spacer 2 0.00011 0.00022
Fork Holer Arm 1 0.12 0.12
Fork 1 0.19 0.19
Front Bearing Rod 1 0.00403 0.00403
Front Wheel Rim 1 0.27 0.27
Tube 2 0.06 0.12
Tire 2 0.0775 0.155
Telescoping Tube 1 1 0.08 0.08
Telescoping Tube 2 1 0.06 0.06
Telescoping Tube 3 1 0.0553 0.0553
Telescoping Tube 4 1 0.08 0.08
Handle Bar Single 2 0.0584 0.1168
Front Wheel Hub 1 0.076 0.076
Frame Front Wing 1 0.165 0.165
End Caps 4 0.00817 0.03268
Rear Wheel Hub 1 0.22 0.22
Rear Wheel Hub 1 0.0369 0.0369
Brake Drum 1 0.08 0.08
Rear Bearing Rod 1 0.0455 0.0455
Brake Casing 1 0.03 0.03
Brake Latch 1 0.0151 0.0151
Case Pin 1 0.000948 0.000948
Brake Caliper 1 0.0296 0.0296
Latch Washer 1 0.000529 0.000529
Latch Nut 1 0.00163 0.00163
Brake Torsional Spring 1 0.00116 0.00116
Small Spacer 1 0.00196 0.00196
Washer with Cut 1 0.00637 0.00637
Rear Wheel Support Left 1 0.118 0.118
Rear Wheel Support Right 1 0.116 0.116
Group 6 pg. 86

89. Motor Mount 1 0.17 0.17
Chain Tensioner 1 0.02 0.02
Chain Tensioner Spring 1 0.00573 0.00573
Chain 1 0.09 0.09
Tensioner Screw 1 0.00354 0.00354
L-Channel 2 0.12 0.24
Battery Tub 1 0.5 0.5
Battery Box Impact Cage 1 0.12 0.12
Battery Tub Cover 1 0.159 0.159
Silicone Deck Padding 2 0.03 0.06
Brake Locator 1 0.00451 0.00451
Brake Locator Washer 2 0.000947 0.001894
Chain Side Guard 1 0.118 0.118
Brake Side Guard 1 0.0862 0.0862
Folding Deck Locator 2 0.0052 0.0104
Folding Deck Locator Silicone
Pad
2 0.00143 0.00286
Folding Deck Spacer 2 0.00044 0.00088
Clutch/Sprocket 1 0.36 0.36
Group 6 pg. 87

90. Cost Analysis
When solving for the overall manufacturing costs and sales price of the scooter several
steps and assumptions were taken. The total manufacturing cost of the scooter come from the
direct labor and the indirect labors that it takes to make one complete scooter assembly. The
direct labor costs come directly from manufactured custom parts, commercial off the shelf parts,
and direct labor cost of the assembly. It is important to note that all calculations were based from
an order quantity of 100,000 scooters.
The scooter was designed with many custom parts made out of different materials and
processes. For example, the custom parts of the wheels are composed of magnesium alloy hubs,
polypropylene rims, butyl rubber inner tubes, and rubber tires. Using customparts.net we were
able to find a cost estimate per part for die casting of the hub and plastic injection molding for
the rims. Using an external manufacturer we calculated the cost of the inner tube and the tires
from an alibaba.com supplier from China that makes custom orders. Other parts like the bearings
and the inner bearing rods of the wheels were off the shelf parts from McMaster Carr. When
dealing with certain custom parts like the rear wheel hub that has threaded features an extra
machining cost was added for the addition of holes and threads.
To calculate for the structural rails and the handle bars an overall weight was taken. By
using the cost of magnesium alloy per unit weight for extrusion applications we found the
manufacturer that would provide pre-cut lengths for all the structural components of the frame.
All buttons pins used for the handle bars and rails were off the shelf parts from McMasters.
The motor was an off the shelf part from electricscooterparts.com. To mount the motor to the
assembly we used custom parts and off the shelf parts. The motor mount was calculated as a
magnesium die casted part from customparts.net. Nuts and washers were calculated as off the
shelf parts from McMaster Carr.
Since we scaled down many parts from the Razor E300 we used those prices as
references. In the scooter design the brake assembly, clutch, and brake drum assembly were all
used. The price of the E300 was used as a references point but this was assumed to be 200%
more expensive due to its smaller size and magnesium components. Other parts like the brake
casing and the brake drum were calculated from customparts.net as die casted parts using
magnesium alloy.
Some of the major components that were off the shelf parts are the front axle (Socket
Drive Post), the Tattu 6S Lipo battery, controller, reset buttons, ON/OFF switch, charger port,
charger, grips for the handle bar, throttle, brake lever, an brake cable among others. These were
all used as a reference price at times. Some of our springs were custom made, but we used
similar McMaster Carr springs as a reference price as well as other parts such as spacers and
rods.
Overall when dealing with custom parts we used plastic injection molding estimators
(side guards, battery box, wheel rims), die casting for magnesium alloy (brake casing, motor
mount, folding mechanism parts), and extrusion applications. An extra uncertainty cost was
added for polished coatings of certain parts and extra machining costs. Tables 7 and 8 show the
list of prices of all prices used in the scooter. Appendix B shows the estimators from
customparts.nets that were used as well as some off the shelf part as guidance for the steps and
processes that were taken to perform a cost analysis.
Group 6 pg. 88

91. Knowing the total assembly time, commercial off the shelf parts price, and manufactured
parts price the total direct cost of making one scooter can then be solved for as seen below:
𝑇𝑜𝑡𝑎𝑙 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡
= ( 𝐴𝑠𝑠𝑒𝑚𝑏𝑙𝑦 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡) + ( 𝐶𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑂𝑓𝑓 𝑡ℎ𝑒 𝑆ℎ𝑒𝑙𝑓 𝑃𝑎𝑟𝑡𝑠)
+ ( 𝑀𝑎𝑛𝑢𝑓𝑎𝑐𝑡𝑢𝑟𝑒𝑑 𝑃𝑎𝑟𝑡𝑠)
Where, the assembly direct cost is assumed to be $50 per hour. The Commercial of the
shelf parts are 50% of the catalogue price due to the large quantity of 100,000 units. Finally, the
manufactured parts are the full cost of producing the custom parts.
To get the total cost of making one scooter we add the total direct cost and the indirect
cost. Where the indirect cost is the total direct cost times a constant K, which in this case is
assumed to be 0.5.
𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡 = 𝑇𝑜𝑡𝑎𝑙 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 + 𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡
𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 = ( 𝑇𝑜𝑡𝑎𝑙 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡) × 𝐾
Because we want to make money as an electric scooter company we get the sales price to
be twice of the total direct cost in order to break even and have a good profit, as seen in the
relation below.
𝑆𝑎𝑙𝑒𝑠 𝑃𝑟𝑖𝑐𝑒 = (𝑇𝑜𝑡𝑎𝑙 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡) × 2
Commercial Off The Shelf
Parts $549.84
Assembly Direct Cost $15.08
Manufactured Custom Parts $96.50
Total Direct Cost $661.42
Indirect Cost $330.71
Total Cost (Indirect plus
Direct) $992.13
Sales Price $1,984.27
Assembly
Time
18.1 min
K constant
for indirect
cost
0.5
Group 6 pg. 89

92. Table 7: Off the Shelf Parts Prices
Part Part # Quantity Cost/part Price
Motor XYD-6B 1 $139.95 $69.98
Battery SKU-2162 1 $570.00 $285.00
Socket Drive Post 97851A204 1 $21.50 $10.75
Rod Clip 51055K413 1 $0.23 $0.12
Sproket 2737T236 1 $17.55 $8.78
Wheel Nut Axle 91982A300 2 $3.63 $3.63
Charger for Battery iCharger208B 1 $126.99 $63.50
Inner Bearing Rod 6391K212 2 $0.84 $0.84
Grips Elec Scoot 2 $3.95 $3.95
Chain Elec Scoot 1 $5.76 $2.88
Case Pin 90145A418 1 $0.95 $0.47
Latch Nut 91841A155 1 $0.08 $0.04
Latch Pin 95648A530 1 $0.30 $0.15
Latch Washer 96659A102 1 $0.03 $0.02
Medium Washer Wheel 91455A140 2 $0.09 0.0897
Wheel Thin Washer 91455A440 1 $0.11 0.0549
Wheel Washer with Cut 91455A180 1 $0.12 0.06035
Wheel Split Washer 91190A560 2 $0.08 $0.08
Silicone Rubber Deck 5787T33 2 $4.37 $8.74
Torsional Spring 9271K631 2 $5.81 $5.81
Brake Lever Elec Scoot 1 $15.95 $7.98
Brake Cable Elec Scoot 1 $2.95 $1.48
On/Off Elec Scoot 1 $5.95 $2.98
Reset Elec Scoot 1 $7.95 $3.98
Speed Controller Elec Scoot 1 $35.95 $17.98
Throttle Elec Scoot 1 $21.95 $10.98
Charger Port Elec Scoot 1 $7.95 $3.98
Wheel Small Spacer 2868T38 1 $0.36 $0.18
Low Voltage Cut-Off Quadcopter 1 $25.99 $13.00
Front Fork Bearing Elec Scoot 1 $11.95 $5.98
Button Pins 94282A290 14 $0.74 $5.15
Group 6 pg. 90

93. Tensioner Screw 92327A279 1 $2.31 $1.16
Motor Mount Spacer 2868T38 1 $0.36 $0.18
Folding Spring 9654K286 1 $0.63 $0.31
End Caps 9474K42 4 $0.25 $0.51
Wheel Bearing 6383k160 4 $4.57 $9.14
Table 8: Custom Parts Prices
Part Amount Cost/part Price
Custom Brake Caliper 1 $1.77 $1.77
Custom Brake Casing 1 $1.37 $1.37
Custom Brake Latch 1 $1.13 $1.13
Custom Clutch 1 $14.95 $14.95
Alibaba Magnesium 6.21 $9.09 $56.45
Custom Motor Mount Top 1 $1.70 $1.70
Custom Chain Tensioner New 1 $0.09 $0.09
Custom Arc 2 $1.33 $2.66
Custom Brake Drum 1 $0.90 $0.90
Alibaba Inner Tube 2 $1.25 $2.50
Nashbar Tire 2 $2.50 $5.00
Custom Black Battery Box 1 $1.81 $1.81
Custom Lid for Battery Box 1 $1.17 $1.17
Custom Chain Side Guard 1 $0.92 $0.92
Custom Front Rim Wheel 1 $1.61 $1.61
Custom Rear Wheel Rim 1 $1.61 $1.61
Custom Brake Side Guard 1 $0.84 $0.84
Group 6 pg. 91

94. APPENDIX A
SOLIDWORKS DRAWINGS
Group 6 pg. 92

95. 31.09 ±0.24
37.09 ±0.29
47.53±0.38
40.42±0.32
16.24±0.12
Scooter Assembly
Unfolded
SHEET 1 OF 1SCALE: 1:20 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:
COMMENTS:
5 4 3 2 1
Dimensions in inches
DRAWING BY:
Matthew DeVries
Group 6 pg. 93

96. 22.84 ±0.18
11.64±0.09 8.06 ±0.06
Scooter Folded
Assembly
SHEET 1 OF 1SCALE: 1:10 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:
COMMENTS:
5 4 3 2 1
Dimensions in inches
DRAWING BY:
Matthew DeVries
Group 6 pg. 94

97. A2
A1
1
A3
2
42
Part/Assembly
Number
Part/Assembly
Name QTY
1 Frame Rail 2
2 Button
Connector 8
3 End Cap 4
A1 Front Section
Assembly 1
A2 Handlebars
Assembly 1
A3 Rear Section
Assembly 1
Scooter Exploded
SHEET 1 OF 1SCALE: 1:50 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:
COMMENTS:
5 4 3 2 1
DRAWING BY:
Matthew DeVries
Group 6 pg. 95

98. 13
A4
14
15
6
7
8
54
17
16
9
10
12 11
18
19
20
21
Part/Assembly
Number
Part/Assembly
Name QTY
A4 Wheel Assembly 1
4 Front Section 1
5 Lock Rod 1
6 Tension Spring 1
7 Lock Rod Spacer 2
8 Clip 4
9 Deck Locator
Washer 2
10 Deck Locator
Silicon Pad 2
11 Deck Locator
Screw 2
12 Deck Locator 2
13 Socket Female 1
14 Socket Male 1
15 Fork 1
16 Fork Guide 2
17 Fork Holder Arm 1
18 Bearing Washer 2
19 Fork Bar Lower Nut 1
20 Fork Bar Washer 1
21 Fork Bar Top Nut 1
Front Section
Exploded
SHEET 1 OF 1SCALE: 1:10 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:
COMMENTS:
5 4 3 2 1
DRAWING BY:
Matthew DeVries
Group 6 pg. 96

99. 2
22
23
24
25
26
27
28
29
30
31
Part Number Part Name QTY
2 Button Connector 6
22 Telescoping Tube 1 1
23 Telescoping Tube 2 1
24 Telescoping Tube 3 1
25 Telescoping Tube 4 1
26 Motor Side Grip 1
27 Motor Twist 1
28 Motor Twist Holder 1
29 Handle Bar 2
30 Brake 1
31 Brake Side Grip 1
Handlebar Exploded
Assembly
SHEET 1 OF 1SCALE: 1:20 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:
COMMENTS:
5 4 3 2 1
DRAWING BY:
Matthew DeVries
Group 6 pg. 97

100. 32
33
36 3837 40 41 A5
42
43
44
45
46474849A6
39
34
35
Rear Assembly
SHEET 1 OF 2SCALE: 1:20 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:
COMMENTS:
5 4 3 2 1
DRAWING BY:
Matthew DeVries
Group 6 pg. 98

101. Part/Assembly
Number
Part/Assembly
Name QTY
A5 Rear Axle Assembly 1
A6 Battery Tub
Assembly 1
32 Rear Section 1
33 Chain Link
Assembly 1
34 Deck Hinge 2
35 Deck Hinge Screw 8
36 Chain Tensioner 1
37 Chain Tensioner
Nut 1
38 Chain Tensioner
Spring 1
39 Chain Tensioner
Screw 1
40 Deck 1
41 Folding Deck
Locator Silicon Pad 2
42 Brake Locator 1
43 Brake Locator Nut 1
44 Brake Locator
Screw 1
45 Brake Side Guard 1
46 Chain Side Guard 1
47 Motor Mount Nut 1
48 Motor Mount 1
49 Motor Mount
Screw 1
Rear Assembly
Exploded
SCALE: 1:20
REVDWG. NO.
A
SIZE
TITLE:
COMMENTS:
5 4 3 2 1
DRAWING BY:
Matthew DeVries
SHEET 2 OF 2
Group 6 pg. 99

102. 53 54 55 56
Part Number Part Name QTY
53 Front Wheel Rim 1
54 Front Wheel Hub
Assembly 1
55 Tube 1
56 Tire 1
Front Wheel Assembly
Exploded
SHEET 1 OF 1SCALE: 1:4 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:
COMMENTS:
5 4 3 2 1
Dimensions in inches
DRAWING BY:
Jonathan Franco
Group 6 pg. 100

103. 50 51 52 50
Part Number Part Name QTY
50 Wheel Ball Bearing 2
51 Front Wheel Hub 1
52 Front Bearing Rod 1
Wheel Front Hub
Assembly Exploded
SHEET 1 OF 1SCALE: 1:2 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:
COMMENTS:
5 4 3 2 1
Dimensions in inches
DRAWING BY:
Jonathan Franco
Group 6 pg. 101