R2 Drive System

Nov 21, 2017

This is the same drive system I have in my first R2 and my R5.  I purchased the material at a local metal supply place for about $30.  The tools I have used were a drill, a hack saw and a jigsaw.  Click on the images for a larger one

Note that I am using 2x4in rectangular aluminum tubing and you will have to check the inside dimensions of your foot shells as it can be very tight.  A 3x4 tubing would work

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Here is the aluminum tubings marked out with a marker to show where I want to cut.  The cross location will depend on your belt length and the diameter of your wheel.  Older scooters had 4in wheels while newer ones had 5in wheels.  My designs have always pushed the wheel as far back of the foot shell as possible for stability.  A jigsaw was used to cut the length of 2x4 to the shorter lengths needed.

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Here is the other side of the tubings.  Note the location of the 3 holes for the scooter motor as the belt or chain will have to miss the motor mount. As you will see later.

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The inside of the 2x4 that will have to be cut out to allow clearance for the wheel, motor and belt

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The top and bottom of the 2x4.  The top has nothing at the moment while the bottom has the hole for the wheel and belt.

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I drill holes to prepare for the jigsaw.

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More holes drilled

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And the final holes drilled.

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The jigsaw takes time but it does work.  If it feels like you are applying a lot of force to get the jigsaw to cut through the aluminum I will put in a new blade.

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I tried to get fancy and angle the jigsaw to get the end pieces angles.  This added some time to the cutting process and was not really needed.

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It did look pretty when I finally got the angled cutting to but in hindsight not worth it.

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Ooooo pretty.

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It took me about 3 hours to do all the cutting with short breaks in there to rest the hand from the vibrations.

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Angled cut vs straight cut.  Yes the angled cut looks nicer but the whole thing looks rough anyways and it will be hidden so the choice is up to you.

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Upper and lower view of the top piece.

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Finally done.  Left and right drive assemblies

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Test fitting the motor to the holes drilled to make sure they fit.  Note:  The motor I got the scooter from has the longer screws and spacers that I used here to mount the motor to the drive system. 

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Just to show the other side.

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Another view.  During the final assembly I actually had to open up the circle a bit more as part of it was hitting the motor housing.

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Another view

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Top view


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