Moped Electrification

In a bid to modernize and upgrade my vintage moped, I embarked on a project to convert it into a hybrid electric vehicle. I had a vision but limited resources, as I was building this in my collegetown backyard with no access to a machine shop and a budget of $300. While I did plan each step, I maintained plenty of room for improvisation to ensure a successful transformation with the limitations I faced.

The cornerstone of this project was the installation of a 48V 1000W hub motor to replace the original front wheel. To power the motor, I bought a 20000mAh 48V battery along with a compatible controller. However, protecting these electronic components against the elements posed a challenge, especially given the moped's intended use in all weather conditions. To address this concern, waterproofing became an important consideration. I sourced a waterproof electronics box to house the battery and controller securely. Carefully mounting the box onto the frame, I routed the wires close to the frame and under the gas tank to maintain a sleek appearance. Using silicone sealant, I sealed the wire entry points at the bottom of the box, preventing any moisture ingress.

Resourcefulness became important in the absence of a fully-equipped workshop. With only a Dremel and a power drill, I had to find unique solutions to fabricate the necessary components. Designing and fabricating a mounting frame for the electronics box became a fun challenge. Utilizing aluminum L-angle bars, I crafted a sturdy frame, cutting and bolting the pieces together to ensure structural integrity.

The conversion process demanded more than just electronic upgrades. With the removal of the original front wheel and its drum brake, the need for a reliable braking system became paramount. Opting for an off-the-shelf cable-actuated disc brake and caliper, I faced the task of engineering a mounting fixture to integrate the new braking system seamlessly. Resourcefulness once again came into play as I designed and manufactured the mounting fixture using a 1/4 inch steel plate, cutting the steel plate with my trusty Dremel, albeit with considerable time and effort.

The completed hybrid ride provided much better acceleration, consistent speed going uphill, and range than the original 2-stroke engine alone. The improved performance has made the moped much more drivable as I am able to maintain speeds of 25mph going up a steep hill where as before I would go around 12mph. Hill performace is a big deal here in Ithaca! The redundancy of two motors means I will never find myself stranded without gas, a situation I found myself in more than once as the gas tank has no fuel gauge. Another smaller quality of life improvement with the electric motor is that I no longer need to kickstart the moped. I simply drive forward on electric power only and pull the clutch, bringing the gas engine roaring to life.

This project developed my skills in:

Problem solving
Mechanical intuition
Resourcefulness
Vehicle systems

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