The Workshop
This is where it all happens. A garage near Highway 7 in Ontario, a pile of parts, and a lot of trial and error. Here is an honest look at how the HWY7 boards get built.
How We Build
Every HWY7 board starts on a workbench, not in a factory. We source components, test combinations, break things, fix them, and iterate until the ride feels right.
This page documents that process — the builds that worked, the ones that didn't, and everything we learned along the way.
// BUILD LOG //
Build Logs
Mini Ride v3 — Motor Mount Redesign
The original motor mount on the Mini Ride prototype was causing vibration at speed. We redesigned the mount geometry and switched to a stiffer aluminium bracket. The result is a noticeably smoother ride above 25 km/h.
Problem: excessive vibration from motor mount flex at higher speeds
Solution: redesigned bracket with tighter tolerances and stiffer alloy
Result: vibration reduced significantly, now testing for durability
Off-Road — Pneumatic Wheel Testing
Switched from solid rubber wheels to pneumatic tyres on the Off-Road prototype. The difference on gravel and uneven pavement is significant — much better absorption and traction. Currently testing tyre pressure ranges and evaluating wear rates.
Tested three tyre pressure settings: 15 PSI, 20 PSI, 25 PSI
20 PSI gave the best balance of absorption and rolling resistance
Wear testing ongoing — need 200+ km before drawing conclusions
Fishtail — Deck Shape Prototyping
Cut and tested three different fishtail deck shapes to find the right balance of flex, concave and tail geometry. The third iteration gave us the carving feel we were after — enough flex for comfort, enough stiffness for responsive turns.
Prototype A: too stiff, no flex, poor carving feel
Prototype B: too much flex, unstable at speed
Prototype C: right balance — moving forward with this geometry
Battery Enclosure — Waterproofing Test
Ontario weather means rain. We tested three different enclosure sealing methods to find a reliable waterproofing approach that holds up to real riding conditions — not just a lab test.
Tested silicone gasket, rubber o-ring, and foam compression seal
Foam compression seal failed after repeated open/close cycles
Silicone gasket with stainless hardware performed best — adopted as standard
Remote Control — First Prototype
Built the first version of our custom remote. The goal is a simple, reliable trigger remote with good range and a clear battery indicator. Current version works but the ergonomics need improvement — the grip angle is uncomfortable on longer rides.
Range: tested to 80m line-of-sight — acceptable for street riding
Battery indicator: working, shows three levels
Ergonomics: grip angle needs revision — causing hand fatigue after 20 min
First Ride — Mini Ride v1
The first real ride on the Mini Ride prototype. It worked — which was the goal. Speed was limited, range was short, and the braking was aggressive, but it moved under its own power and didn't fall apart. A good starting point.
First ride: parking lot test, approximately 500m
Top speed achieved: limited to 15 km/h for safety
Key issues identified: braking too aggressive, deck too stiff, remote range limited
// TOOLS OF THE TRADE //
What's in the Workshop
Angle grinder
Cutting and shaping metal brackets and motor mounts
Drill press
Precision holes in deck and enclosure components
Soldering station
ESC wiring, battery connections and remote electronics
3D printer
Rapid prototyping of brackets, enclosure parts and remote housings
Multimeter & oscilloscope
Diagnosing electrical issues and verifying motor signals
Torque wrench set
Consistent fastener torque on trucks, wheels and motor mounts
Follow the Build
We post workshop updates, test ride footage and build progress on Instagram. Follow along if you want to see how this develops.
@hwy7longboard