Extended deck and carbon fiber platform for Dualtron: more space, improved riding position, and enhanced stability
A longer deck primarily serves one purpose: to provide more space. On a modified Dualtron, the larger battery and more powerful controllers no longer fit within the original deck. Extending the deck allows everything to be housed neatly inside, rather than attaching enclosures to the outside. It also provides a larger surface area for foot placement, which changes the riding posture at high speeds.
The essentials
- The deck is the platform that houses the battery and electronics; the footboard is the plate where you place your feet.
- A longer deck allows for a larger battery and more powerful controllers to be housed within the machine.
- Our Thunder kit extends the total length to 670 mm, with 620 mm of usable length; our Victor kit measures 605 mm, with 557 mm of usable length.
- The routing of the phase cables and sensor wires is planned, as are the mounting points for the controllers.
- This is a performance part designed for track use and should be paired with high-quality brakes and steering components.
Why does the original deck become too small?
Modifying an electric scooter almost always involves upgrading the battery: more cells in series to increase voltage, and more cells in parallel to increase current and range. Our guide on batteries and BMS systems that cut out explains why the battery is the primary factor in performance. The problem is straightforward: these additional cells take up space, and the original deck was designed with the original battery in mind.
The aftermarket controllers are also larger than the original ones, and they need to be securely mounted, protected, and have good thermal contact to dissipate their heat. Without proper mounting, you end up with controllers exposed to the elements, vulnerable wiring, and a less robust machine.
The kit for Dualtron Thunder 1, 2, and 3
Our extended carbon fiber deck and plate kit for the Thunder includes a 5mm reinforced aluminum deck, a carbon fiber plate, and 3D-printed PETG black covers. According to its specifications:
- Total length: 670 mm, with 620 mm of usable length
- Designed to accommodate a battery pack with up to 22 cells in series and 11 in parallel, using the 21700 format, and featuring C350-type controllers, or controllers of a similar format, housed within
- Mounting points are provided at the front for the C350 and CL350 controllers
- Cable routing on the right side for the motor phases, Hall sensors, and temperature sensor
- Mounting screws and covers are included.
Ce bac de 670 mm est le même que celui de la RM-X, notre machine de record. C'est aussi la base de notre projet de carénage Formula Escooter, qui existe en version Thunder d'origine et en version châssis rallongé.
The kit is compatible with Dualtron Victor, Luxury, Luxury Plus, and Compact models
Our extended carbon deck and platform kit for the Victor follows the same principle on a more compact machine. Its specifications indicate:
- A 3mm aluminum deck, a glossy carbon fiber plate, and black PETG covers
- A total length of 605 mm, of which 557 mm is usable
- Mounting brackets designed for an Spintend Ubox 85V 240A controller, with its heatsink positioned underneath
- TPU gaskets for cable passages and a cover with an XT90 charging port
- The cable routing on the right side is for the power phases and sensors.
| Kit | Deck | Total length | Usable length |
|---|---|---|---|
| Thunder 1, 2, 3 | Reinforced 5mm aluminum | 670 mm | 620 mm |
| Victor, Luxury, Luxury Plus, Compact | 3 mm aluminum | 605 mm | 557 mm |
What this means for the rider
A longer deck provides more freedom for foot placement. At high speeds, it's beneficial to be able to spread your weight, with one foot forward and the other back, to absorb acceleration and braking forces without feeling restricted. This is a matter of comfort, but more importantly, it's about control: a rider who is properly positioned transmits fewer unwanted movements to the handlebars.
The weight distribution also changes: a larger battery, well-centered and low within the deck, lowers the center of gravity compared to external enclosures. However, the machine becomes heavier, which is noticeable during braking and when handling it.
Carbon fiber: Why use it on the deck?
The deck doesn't support the machine's structure; instead, it forms the base, closes the platform, and provides a surface for the rider's feet. The carbon fiber used in the deck offers lightness and rigidity, resulting in a low weight, and features a distinctive finish. The main structural components, however, remain aluminum, as the deck is designed to absorb the forces generated by the arms, the central column, and the battery.
Here's what you need to consider:
- The battery: The extended deck is only worthwhile when paired with a battery that fills the space. See our batteries for Dualtron.
- Voltage: Switching to a higher voltage requires compatible controllers and a suitable charger. Our guide on upgrading to a higher voltage details the potential pitfalls.
- Wiring: Longer phase and battery cables, connectors sized for the current.
- Brakes and Steering: A heavier and more powerful machine must stop and steer accordingly. Our guide on preparing a Dualtron Thunder outlines the necessary steps.
Workshop tip
Plan out the complete setup before ordering the deck: battery, controllers, wiring, charging port. The extended deck is the foundation that makes everything else possible, but it should be chosen based on what it needs to accommodate, not the other way around.
Frequently Asked Questions
Is the Thunder kit compatible with all three versions?
Yes, it is designed for the Dualtron Thunder 1, 2, and 3 models. However, the other components required for the conversion (battery, steering column, controllers) will vary depending on the specific model.
Can the original battery be kept when using a longer deck?
Technically, yes, but the kit then loses most of its appeal. It was designed to accommodate a larger battery and more powerful controllers inside.
Are the 3D-printed covers durable?
They are printed in PETG, a plastic that is more resistant to heat and impacts than most commonly used printing plastics. They provide a cover and protection; the underlying structure remains aluminum.
Can a scooter with an extended deck be used on roads?
A machine prepared in this way far exceeds the 25 km/h speed limit allowed on public roads. It is intended for use on closed circuits and private property only.