Tasked with creating a working electric ATV prototype from a gasoline model—using only the new Hero EV scooter’s battery and motor—I started with no CAD, just the physical ATV. The first step was to carefully 3D-scan the chassis, which allowed me to reverse engineer and build a precise CAD model for all modifications.
Using the scanned model, I identified key areas for frame modification to fit the large EV battery. The original two-wheeler hub motor wasn’t compatible with the ATV’s axle layout, so I engineered a custom chain drive with a 1.5:1 reduction to give higher torque for climbing and off-road use.
The fabrication phase involved hands-on work—cutting, welding, and reinforcing the ATV chassis. I adapted all the wiring, built custom mounts for the motor and battery, and assembled everything directly on the vehicle in the workshop.
The converted ATV was field-tested on a rough off-road track for a full 2 hours—climbing, jumping ramps, and handling demanding terrain—until the battery was depleted. The prototype finished the test with zero structural or electrical failures, and the custom drive delivered the torque and response needed for real-world performance.