Electric Skateboard - The Beginning (Age 14)

I started this project from scratch back in 2020 when I was just 14 years old. The initial goal was simple: build a functional, reliable electric longboard. I began with a pre-bought battery pack and a standard hub motor setup. Driving these was a VESC (Vedder Electronic Speed Controller), which I custom-tuned to safely manage the power draw and braking curve, maximizing performance while maintaining safety limits.

Fabrication & Sealing

Protecting the sensitive electronics underneath a flexible longboard deck poses unique challenges. Initially, I fabricated enclosures out of fiberglass and epoxy—learning how to lay fiber and resin to create high-strength compartments without relying on thick, heavy plastics. Sealing these rigid boxes tight against the curved, flexing deck was tricky, so I iterated heavily on the gasket designs. Over the years, the design evolved to incorporate an internal rubber seal fixed to the board itself before attaching the housings, significantly improving water and dust resistance.

Upgrades: 3D Printing & Belts

As the project evolved, I wanted to upgrade to larger pneumatic wheels for better stability, but this heavily reduced the torque provided by the standard hub motors. Instead of accepting the performance loss, I pivoted to a custom belt-drive solution.

I completely 3D modeled and printed custom pulleys to mate the new wheels with external motors, ensuring I kept the original top speed while massively boosting torque. During this transition, I also leveraged my new 3D printing capabilities to design custom, modular CAD enclosures that fit the electronics far more snugly than the previous epoxy molds.

Custom High-Voltage Battery Pack

To feed the upgraded belt-drive system and increase range, I eventually needed to move past pre-bought packs. I designed and constructed a custom high-performance battery using spot-welded Molicel P42A cells. Configured in a 12s2p array, this pack required meticulous attention to detail and a serious approach to high-voltage safety. I integrated a dedicated balance charger and BMS (Battery Management System) to ensure all cells charged equally and discharged safely under heavy load.

The Completed Board

The culmination of years of iterative engineering, CAD modeling, electronic design, and hands-on fabrication produced a highly reliable, incredibly fast, and rugged electric longboard that I daily-drove. The project evolved from a basic hub-motor setup into a powerful, custom-belt-driven machine with a robust battery and reinforced enclosures.