I started this project with the goal of making a motorized scooter with parts I was given for free or got out of bulk trash junk piles. The scooter I made was far from a good motorized scooter but I was able to make a rideable scooter for about 15$ total.
Supplies
Jb Weld Weed eater/string trimmer Razor electric scooter Piece of scrap angle iron Various nuts and bolts Small piece of key stock A 1/4 socket you don’t mind sacrificing Optional: spare carburetor, small metal tube, small 2in piece of metal plate
Step 1: The Scooter
I got my scooter for free from a friend who broke the electric motor controller and wanted it out of his shed. The scooter is a razor e100. I started by unscrewing the top plate, this reveals a battery and electronics in a small plastic tray. To get the tray and internals out you first have to remove the electric motor.
Step 2: The String Trimmer
My engine donor I also got for free! The driveshaft tube was broken off the front plastic when I had got it. I got the engine to sputter on the carburetor it came with but it wouldn’t run so I took out the wallet and bought a new one for $9 this ended up being the most expensive part of the project. *save the old carb if you want to do the optional exhaust modification*
Step 3: Clutch and Sprocket
For this scooter I wanted to use the clutch in the trimmer. I took the little gear off the electric scooter and used Jb weld, a socket, and two pieces of key stock to make an adapter so the clutch would drive the gear.
Step 4: Mounting and Chain
For the mount I drilled two holes for the motor in a piece of scrap angle iron then bolted it to the engine. I then put the clutch assembly back on to eyeball the final mounting positions. I drilled one final hole when I found my position and bolted the piece of metal to the scooter frame where the back wheel cover would mount. This served as an alright mount as I could still flex it enough to align the chain. I HIGHLY recommend reinforcing it after you get the chain on
Step 5: Final Touches and Optional Exhaust Rerouting
I needed to mount the fuel tank to the scooter I used the wheel cover mount on the opposite side of the engine and bent it 90 degrees to bolt to the center hole of my gas tank. As I was mounting the engine I realized the exhaust was going to blow right on the riders legs. I found out the old carburetor has the same hole pattern as the exhaust side of the engine too. I took the old carburetor apart and discovered it had a hole that would face downwards so I used the rest of the jb weld I didn’t use on the clutch to add a bent piece of scrap pipe as a side exit exhaust.
Step 6: Recommendations and Final Thoughts
This scooter has many imperfections to say the least. I highly recommend anyone building a scooter like this to not use a 28cc engine, it has no power at all and will not move you without help. I also recommend if you have access to a welder pull it out and use it the motor mounting would be so much easier and sturdy. If you have an intact top cover for the scooter it would be very easy to cut around the motor so you have a good place to stand mine was broken anyway so it didn’t go back on. The optional exhaust was effective in diverting exhaust gasses but it was also incredibly loud. Overall this project could be improved but for almost free I’m happy with the results, had a blast making it, and makes me want to build a better more reliable version of it.
