Build a Gas Scooter

Using a plain old scooter and a chainsaw engine, you can build your own gas powered vehicle.

Steps

  1. Get a scooter with hand brakes and inflatable tires. Scooters with hand brakes have the best stopping power. Inflatable tires allow for the vehicle to handle rougher terrain. Child scooters such as the "razor" are not suitable for this project, because they use hard rubber wheels with pre-pressed bearings. One may also build a scooter frame (requires welding).
  2. Prepare the chainsaw engine by removing the bar and chain from the machine. Leave the rest of the chainsaw intact. Leaving the motor in the chainsaw housing makes it easier to attach to the scooter’s deck.
  3. Unscrew the chainsaw’s centrifugal clutch from the crankshaft. The power from the motor will be transmitted through sprockets and a bicycle chain. The obvious problem with this approach is that you will never be able to "idle" with the engine running and the scooter stationary, and you will have to lift the rear wheel off the ground to get it started. One may also keep the clutch, and use a chain that can fit to the sprocket on the clutch bell. If your chainsaw uses a 2-stroke motor (you have to add oil to the gas) make sure to leave the centrifugal clutch on. Coasting down a hill without the clutch will eventually burn out the motor, since the motor will be forced to move without the lubricating fuel-oil mixture.
  4. Bolt the other sprocket to the rear axle of the scooter. This may be easier said than done--carefully select your scooter knowing that you may have to modify the rear wheel mount, and fix the sprocket onto the rear wheel.
  5. Place the motor on the rear of the scooter platform to ensure the sprockets are in-line.
  6. Drill holes through the platform and chainsaw motor housing so that they can be bolted together. Note that most modern chainsaw housings are made of plastic and you will need to be very strategic about where you are attaching bolts, and the size of washers you use (to keep them from just pulling through the plastic).
  7. Wrap the bike chain around the sprockets. Remove the necessary amount of links so that the chain is tight.
  8. Attach the hand accelerator to one of the handle bars.
  9. Wire the hand accelerator to the ‘on and off’ wires on the chainsaw motor. This allows the rider to control when the engine will power the scooter.

Tips

  • The motor supplies a substantial amount of torque on the gears. If the gear slips and does not rotate with the shaft, one may need to weld the gear in place. This will provide maximum strength and guarantee that the gear will not slip again.
  • If you have trouble installing a hand accelerator, other options such as a small pedal should be investigated.

Warnings

  • Make sure to check if there are any ordinances against riding this type of scooter in your area.
  • Be careful when using the scooter. It is capable of traveling at fast speeds and could cause injury.
  • Try to only ride on relatively smooth roads. Potholes can cause some nasty accidents.
  • Adding a chain guard or gear guard, a protective cover to prevent hands, clothing, or other objects from being caught in the drive mechanism, can prevent potential accidental injuries.

Things You'll Need

  • Self-propelled kick scooter
  • Chainsaw engine (still in plastic/metal case)
  • chain
  • Various bolts, nuts, and washers
  • Dirt bike hand accelerator
  • Single Pole, Single Throw (SPST) switch
  • Electric Drill
  • Bicycle chain link extractor tool (to adjust tension in bike chain)
  • Optional:Welder, various metal fabrication tools.
  • Make sure that you have a hand brake!

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