Preparing a Dualtron Thunder: The order of operations, from the motor to the controllers
The Dualtron Thunder is one of the most customizable electric scooters: its foundation is solid, its components work well together, and it can handle a lot of power, provided you give it the right support. The common mistake is to start with the power. The workshop takes a different approach: first, focusing on what stops and directs the machine, and then on what makes it move forward.
The essentials
- The order is as follows: brakes, tires and rims, steering, battery, motors, controllers.
- The battery is the primary factor influencing performance: without power, neither the motors nor the controllers are effective.
- The Thunder 1, 2, and 3 models have different original voltage specifications, and each battery change is verified using the controllers.
- The available space on the deck is the real limitation of a Thunder; it can be addressed by using a longer deck.
1. Brakes, above all else
A tuned Thunder scooter goes fast. The braking system must keep up before the first extra amp is added. On our racing machines, we install Hope Tech 4 V4 brakes, with four-piston calipers and aviation-grade hoses, along with reinforced brake discs that are 3 mm thick, such as the BrakeStuff 180 mm disc, which has been tested at speeds exceeding 147 km/h on a track. Our guide on braking for a powerful electric scooter details these choices.
Our CNC-machined arms for Dualtron feature a caliper mount on both sides and maintain the original arm length: they install without modification on Thunder 1, 2, and 3, Achilleus, and Victor models.
2. Tires and Rims
All the power is transmitted through two small rubber surfaces. Tires that are appropriate for the intended use (road or track) and in good condition are essential before increasing the power. See our tires and rims.
3. The Steering System
On powerful machines, the original steering column develops play at the folding mechanism, becoming loose and flexing during fast turns. A steering column that moves at high speed is dangerous. Our grade 9 titanium steering columns, with an aluminum 7075 stem and adapter, eliminate this play; they mount to the original folding mechanism and require a mountain bike-style stem. They are available for the different versions of the Thunder: see our mechanical parts.
4. The battery
It's the primary factor affecting performance. The original battery limits the available current; demanding more can cause interruptions, as explained in our guide Battery and BMS causing acceleration cut-offs.
Our Performance batteries for the Thunder and Thunder 2 are a game-changer. Our Performance 80V 32Ah battery specification boasts a peak discharge current of up to 320A, compared to 140A for the original battery, and features a connected BMS (Battery Management System) that allows you to monitor the status of the cells via your phone. Here are three key points to consider, based on our specifications:
- Thunder 1: Originally equipped with a 60V system. Upgrading to a higher voltage battery requires changing the controllers. See our guide on upgrading to a higher voltage.
- Large capacity: Our 72V 40Ah battery occupies the entire interior of the deck; therefore, the controllers must be installed externally.
- Charger: It must be compatible with the new battery.
See all of our batteries for Dualtron.
5. The deck: the platform
More cells and larger controllers require more space. Our extended carbon fiber deck and platform kit for Thunder 1, 2, and 3 increases the total length to 670 mm (620 mm usable). It is designed to accommodate a battery pack with 22 cells in series and 11 in parallel, using a 21700 format, with C350-type controllers inside, and provides space for routing phase and sensor cables.
6. The Motors
Our SHS60 and SHT60 motors are compatible with Dualtron Thunder models, featuring an integrated tubeless rim. For a more advanced track preparation, our Thunder 1 Evo has been upgraded with XHS-75 motors, CNC rims, and slicks. The choice between High Speed and High Torque is explained in our guide High Speed or High Torque.
7. The Controllers
Finally, once the battery can supply the current and the motors can handle it, adjustable controllers allow for precise adjustment of the current supplied to the battery and the motors. The Thunder 1 Evo that we prepared for the track uses C350 controllers. See our controller guide and our controller comparison.
Workshop tip
After each step, ride and check: tightenings, temperatures, connections. Performing all the preparation work at once makes it impossible to determine which modification caused a problem.
And what about the law?
A modified Thunder scooter significantly exceeds the 25 km/h speed limit allowed for electric scooters on public roads. It is designed for track use and private property. See our guide on laws and unlocking.
Frequently Asked Questions
What's a good starting point for someone on a tight budget?
First, the brakes and steering, for safety, followed by the battery, which eliminates interruptions and provides power to the entire system. Then come the motors and controllers.
Are the parts the same for the Thunder 1, 2, and 3 models?
Not all parts are interchangeable. While the CNC arms and extended deck are compatible with all three models, the batteries, original voltages, and steering columns differ depending on the version. Please check the compatibility on each product page or contact our workshop for assistance.
How long does a Performance battery last?
Our batteries are assembled to order in our workshop in France; the manufacturing lead time is indicated on each product page.