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My Home Made E-Bike

Discussion in 'EV (Electric Vehicle) Discussion' started by usnavystgc, Oct 21, 2014.

  1. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    2013-06-25_10-06-59_842.jpg
    Several members have been asking me about the e-bike on my avatar so rather than PM each of them, I thought I'd just start a new public thread.

    I made this e-bike about three years ago and have been riding it ever since. You can ride it in one of three modes, full electric, assist, or regular bicycle mode.

    The specs/info I've come up with after almost 3 years of riding and testing are listed below. All are based on a 210 lb rider (aka me) with relatively flat terrain and no assist from me (if you want to compare to other e-bikes, you should understand that those specs assume flat terrain and a 185 lb rider). Speed is approx. 15 mph average. Higher speeds will of course net you less range (and vice versa with lower speeds) but, I ride it wide open most of the way to and from work (6 miles one way) and have yet to run low on battery (charge at work just to be safe).

    Bike: Motobecane Gran Turismo 27 speed Touring Bike (excellent bike for $699)
    Battery: 24V/30ah battery pack made from 16 Headway 40152S Cells taped together in a triangle pattern with duct tape to allow it to fit in the triangle pack
    Motor: Currie 24V/900Watt electric scooter motor
    Range: Approx 17 miles
    Controller: Kelly 24vdc/50A controller
    Control: Thumb throttle
    Sprocket: Custom Freewheel modified sprocket (see pic)
    Charging time: 25 min's for a 60% charge, 2 hours for a full charge (this could be dramatically shortened with a better charger but, that means more expense as well)
    Cost: If you DIY everything, of the shelf parts cost about $2000 (including the bike), $1300 without the bike

    The batteries are the main cost since each cell is $35 (approx.) by the time you pay for shipping. 35 X 16 = $560. You can get them cheaper but, not much. There are also a lot of miscellaneous parts like clamps, hose clamps, aluminum stock, metal bar stock, sprocket freewheel bearing, charger, motor, throttle, BMS etc. It adds up quick.

    It's not cheap but it is a lot of fun and rewarding to ride reliable transpo that you made. Even better, I work in an office so if I have a meeting and have to wear a suit, I can ride in without sweating. I can go up most hills around here in full electric mode and never go below 15 mph.

    Here's a pic of the freewheel sprocket which enables the motor to drive the chain without the pedals turning.

    [​IMG]
     
    bisco and Cheapergear like this.
  2. hill

    hill High Fiber Member

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    Vehicle:
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    Nice DIY project! I - not being the master of my own time / schedule / universe, had to do the off the shelf method. Pedego, in metalic Olive Green. It's great, except for the flourecent valve stem caps. The tops split out from over tightening ... if you call 5 or 6 inch Lbs over tightening.
    [​IMG]

    got about 1,500 miles on it so far. I'd love to upgrade to the 48v pack ... but again ... she-who-must-be-obeyed has veto power ... so, no dice.
    ;)

    Did you consider a hub motor? There seems to be a jillion kits available on line now days. If they'd have been available prior to selling my lightning brand recumbent, I'd have installed one on it, and never looked back.
    .
     
    usnavystgc likes this.
  3. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Four
    Hi Hill,
    Yes I did consider a hub motor and it just doesn't offer the versatility that I personally wanted. The mid mount motor offers so much versatility. Every gear is available to me so climbing any hill is no problem. And I can easily select the desired amount of assist by selecting a combination of gears and throttle. :)
     
  4. dbcassidy

    dbcassidy Toyota Hybrid Nation, 8 Million Strong

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    Great thread, I converted the wifes' and mine bikes to EBike conversion 2 years ago. This has really helped with helping on long trips thru the hilly / mountain areas. The electric assist helps with my problematic right knee.
    We use direct drive front hub motors on our mtn bikes. We don't off road much these days, mostly use bike paths or sides of roads with a bike lane.
    the LIon batt packs locks onto the rear double decker bike rack. We can get upto 22 mph and upto 18 - 24 miles range.

    I have to take and post photos when I have some free time from the constant plowing / digging out of 8 feet and counting from this nasty winter.

    I really miss riding the EBike and cant wait for SPRING to start riding again.

    DBCassidy
     
    bisco and usnavystgc like this.
  5. Plusfun

    Plusfun New Member

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    That's pretty awesome. Nicely done!
     
    usnavystgc likes this.
  6. KennyGS

    KennyGS Senior Member

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    Not enough seat for me, but impressive nonetheless. (y)
     
    usnavystgc likes this.
  7. Dxta

    Dxta Senior Member

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    I know this is some dunken years old thread right now, but the ideas presented here are cool.
    How were you able to hook up that huge motor to drive the flywheel sprocket, in such away that if someone is starting this project from scratch, would get it going?
     
  8. hill

    hill High Fiber Member

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    There are e-bikes from manufacturers now that can go between 40 and 90 miles per hour so yes this is a zombie thread.