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Old 2nd November 2015, 16:27   #1
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Cool Building a 'Pocket Bike' out of a TVS Scooty ES

I'm in the process of making pocket bike out of Scooty ES for a 12 year old kid. Idea started some 4 years back and I could make it happen now.

Disclaimer:
- This bike will not be taken to public roads.

Base Vehicle Details:
Make : TVS
Model : Scooty ES
Year : 2000

Why Scooty ES?
Scooty ES is the cheapest and safe best. People suggested to get Kinetic Honda or Bajaj Sunny which are available at scrap rates. Those samples I came across were already at their end of life, few rust buckets with bits and pieces of broken plastic around. The subject Scooty is single owner, well maintained and mechanically fit with valid documents. Without a second choice got her and started stripping.

Modifications Planned:
- Length & Height reduction
- Single Seat
- Exhaust routing under the seat
- Fuel tank in the front (Bike like)
- Limiting Top speed (Yet to finalize how to control)

Posting few snaps now. Let me update the progress every evening.

Base vehicle
Building a 'Pocket Bike' out of a TVS Scooty ES-01.jpg

Building a 'Pocket Bike' out of a TVS Scooty ES-02.jpg

Building a 'Pocket Bike' out of a TVS Scooty ES-03.jpg

After 30 mins
Building a 'Pocket Bike' out of a TVS Scooty ES-04.jpg

Building a 'Pocket Bike' out of a TVS Scooty ES-05.jpg

Building a 'Pocket Bike' out of a TVS Scooty ES-06.jpg

Building a 'Pocket Bike' out of a TVS Scooty ES-07.jpg

Started chopping the unwanted bits & pieces
Building a 'Pocket Bike' out of a TVS Scooty ES-08.jpg

Building a 'Pocket Bike' out of a TVS Scooty ES-09.jpg

Building a 'Pocket Bike' out of a TVS Scooty ES-10.jpg
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Old 3rd November 2015, 09:07   #2
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Default re: Building a 'Pocket Bike' out of a TVS Scooty ES

Wheelbase reduced by 200 mm
Chopped the frame and welded
Building a 'Pocket Bike' out of a TVS Scooty ES-11.jpg

Building a 'Pocket Bike' out of a TVS Scooty ES-12.jpg

Building a 'Pocket Bike' out of a TVS Scooty ES-13.jpg

Exhaust routing to be modified. Stock silencer bend will harm the kid's leg
Building a 'Pocket Bike' out of a TVS Scooty ES-14.jpg
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Old 3rd November 2015, 11:26   #3
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Default re: Building a 'Pocket Bike' out of a TVS Scooty ES

Nice idea sir ji!!

One suggestion: please add speed governor of some sort. (doing 60kmh is not good)ke design

Do consider reverse trike design, it will be much safer for the kid.
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rgds,
Nikhil

Last edited by jeepster : 3rd November 2015 at 11:30. Reason: added pics
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Old 3rd November 2015, 11:38   #4
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Default re: Building a 'Pocket Bike' out of a TVS Scooty ES

Quote:
Originally Posted by jeepster View Post
Nice idea sir ji!!

One suggestion: please add speed governor of some sort. (doing 60kmh is not good)ke design

Do consider reverse trike design, it will be much safer for the kid.
Thanks Nikhil. I'm currently working on the speed governor (yet to finalize)
3 Wheeled proposal looks good and confident inspiring, may be I will keep it for future project.
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Old 3rd November 2015, 14:07   #5
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Default re: Building a 'Pocket Bike' out of a TVS Scooty ES

Proposed Exhaust routing
Building a 'Pocket Bike' out of a TVS Scooty ES-14-copy.jpg
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Old 3rd November 2015, 15:10   #6
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Default re: Building a 'Pocket Bike' out of a TVS Scooty ES

Cool project, and lucky kid!

Quote:
Originally Posted by Mr.Boss View Post
Wheelbase reduced by 200 mm
Chopped the frame and welded
One concern with this particular part of the modification is altering the bike's front fork rake. Even small changes here can create very different behaviours due to the altered geometry. Not sure how aware you are of this, but I suggest you do some reading on the topic to be safe.

I had once changed the front fork on my mountain bike to a slightly taller one with more travel and a different offset. As a result, my bike became a little more twitchy (which is fine), but the crazy part was that if I turned my handlebars more than a certain amount, the front wheel would have a tendency to buckle, turning around to almost face me -- which resulted in me flying off my bike several times, at the most unexpected & slow moments.

Just mentioning this so that you're aware and can check out the bike thoroughly before handing it over.

Last edited by Rehaan : 3rd November 2015 at 15:11.
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Old 3rd November 2015, 16:13   #7
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Default Re: Building a 'Pocket Bike' out of a TVS Scooty ES

Interesting project you got there.

What are you plans for the suspension or planning to keep the stock ones?

Also like Rehaan mentioned, with reduction in wheel base the rake and trail dimensions have now changed quite a bit. Hope this was kept in mind?

If it is for a 12 year old, i would first focus on safety and stability more than the speed. Ideally lock it to 35-40 kmph by restricting the carb slides.
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Old 3rd November 2015, 16:36   #8
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Default Re: Building a 'Pocket Bike' out of a TVS Scooty ES

Thank you Rehaan & Jaggu for the suggestions.
Quote:
Originally Posted by Rehaan View Post
One concern with this particular part of the modification is altering the bike's front fork rake. Even small changes here can create very different behaviours due to the altered geometry.
Rake & Trail remains unaltered. Double checked by measuring with an inclinometer.
Quote:
Originally Posted by Jaggu View Post
What are you plans for the suspension or planning to keep the stock ones?

If it is for a 12 year old, i would first focus on safety and stability more than the speed. Ideally lock it to 35-40 kmph by restricting the carb slides.
Stock Suspension will remain as of now. In future I may upgrade to better telescopic forks in the front. I'll take any suggestions on this subject for future upgrade (I understand the stock setup will spoil the fun)
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Old 3rd November 2015, 16:47   #9
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Default Re: Building a 'Pocket Bike' out of a TVS Scooty ES

@Mr.Boss,
Warning: Shorter wheelbase will increase the rear wheel displacement angle, which in turn reduces the directional stability. Moreover, load transfer during acceleration and breaking will be higher. Chopping the frame is going to affect CG too. Sorry, but I am not sure you should be doing these modifications, especially when the modded vehicle is to be used by a 12 year old. I hope you do extensive testing.
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Old 3rd November 2015, 16:51   #10
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Default Re: Building a 'Pocket Bike' out of a TVS Scooty ES

Quote:
Originally Posted by Mr.Boss View Post
Stock Suspension will remain as of now. In future I may upgrade to better telescopic forks in the front. I'll take any suggestions on this subject for future upgrade (I understand the stock setup will spoil the fun)
Yes its got minimal travel so wont be great on broken stuff, but smoother surface would be just fine. Also the brakes are ok only for speeds under 40, above that they take quite a while in scooty.

Replacing the front will be a more complex task, the new TVS vigo is the one's that comes to mind that would be kind of within limits for this project.
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Old 4th November 2015, 18:02   #11
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Default Re: Building a 'Pocket Bike' out of a TVS Scooty ES

Cool project! I am totally hooked to it. It's really interesting to see how the project shapes up day by day. Do you have a vision of how the bike is going to be? I would really love to see a cute little chopper
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Old 5th November 2015, 12:50   #12
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Default Re: Building a 'Pocket Bike' out of a TVS Scooty ES

Nice work !!

I have a feeling the end product might resemble the "Bobby" bike from Rajdhoot.

All the best.
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Old 9th November 2015, 12:34   #13
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Default Re: Building a 'Pocket Bike' out of a TVS Scooty ES

Infected by Viral fever for past 1 week and I'm getting recovered now. Sadly I will be travelling abroad in a couple of days and this project will be put on hold for another 4 months

Quote:
Originally Posted by psurelia View Post
Do you have a vision of how the bike is going to be? I would really love to see a cute little chopper
Quote:
Originally Posted by pugram View Post
I have a feeling the end product might resemble the "Bobby" bike from Rajdhoot.
A mix of Chopper and Bobby
Kid loved Thunder Bird and this bike will have the design hues of the same.
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Old 9th November 2015, 16:10   #14
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Default Re: Building a 'Pocket Bike' out of a TVS Scooty ES

https://en.m.wikipedia.org/wiki/Pit_bike
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Old 1st March 2017, 23:06   #15
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Default Re: Building a 'Pocket Bike' out of a TVS Scooty ES

It is over 1.5 years and the project is left untouched doe to several reasons and commitments. I'm finding difficulties in getting leisure time or an appointment from my beloved mechanic (for this particular work) to resume the job. Left with only 2 options now
- Get it done before this summer (that's the time frame given by home minster to clear the space)
or
- Trade off

If I couldn't succeed with option 1, let me know if someone could take-up this project.
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