My first E Bike project.

schulze 123

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Dec 20, 2010
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Location
Adelaide, Australia
Hi Troops,
After building two internal combustion powered bicycles I decided to undertake an 'E bike' project for operation in noise sensitive locations such as the beach front on a summers evening. The base bike for this project was a Repco Tungsten which was bought from the local porn broker for $85.00. The alloy frame and wheels are the only thing that I will keep, the rest will be upgraded as the project moves along. The planned outcome of this project is a bike that will have a peddle assisted range of 30km and an on the flat top speed of around 38kph, anything more than this on both parameters will be a bonus.
I don't expect this to be a lightening build but I will post info and images of the progress as the budget and time permits. All of the suspension and brake upgrades have been ordered and should start to arrive in the next few days.

Let the journey begin.

Cheers BJ
 

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Hi Wheelbender6,
I should have stated the type of drive (oops), it will be a chain drive via the front chainring so that I will have seven speed gearing via the rear cluster. A Nuvici rear hub would be better but the budget won't stretch that far at the moment.

Cheers BJ
 
Hi Neon,
Yes, I will have a freewheel on the front chainring and also on the sprocket from the motor so that when the motor is not in use it won't be driven by the pedals.
Quite a bit of the ordered goodies turned up today and I have begun the fit out, so I will post some images of the progress tomorrow.

Cheers BJ
 
Hi Troops,
As stated in the previous post some of my goodies had arrived and I've been busy fitting them to the frame. The first shot is of the pile of removed items and the rest are of the new items fitted. The new forks and drive system have yet to arrive but this will allow me to carry out some of the other work that is needed without the distraction of more 'Shiney' items.
A bit about the drive unit, the motor will be a large 'Outrunner' style (6500 watts Max. output) connected to a 4:1 tooth belt reduction system with a slipper clutch to protect from shock loads. From there we go to 2:1 chain reduction with a free wheel (to isolate the motor from the drive train when not in use) this is connected to a modified Sick Bike Parts jack shaft kit to the chainring. Power will be in the form of a 10s2p LiPo pack with a capacity of 16Ah. This all sounds a bit complicated but when it all becomes reality you will see that it is quite the opposite. I will more than likely make a cardboard mock up of the installation to show the layout and this will also assist in making sure it all fits before getting the 'Man with Mill' too excited.

If anyone has any comments or questions, please feel free to do so.

Cheers BJ
 

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You're not messing around as far as power goes. 8hp max is a lot of power. You certainly wouldn't need to pedal at all. Doesn't sound complicated to me at all. Any plans for a controller or does the motor have one already in it? Please keep posting progress as this is shaping up to be one beast of a machine. Actually you're making me drool.
 
Hi Neon,
My plan here is not to use the motors maximum power but more so it's torque. The gearing I have chosen is quite low so that at wide open throttle the speed of the front chainring will be approx 125rpm and at cruze throttle about 70-80rpm. This speed I can easily pedal at and use the rear cluster gears to alter the road speed this also keeps the motor out of the high current draw range that occurs above 2/3 throttle.
The ESC I have for this project is a Castle Creations Ice 160HV.

Cheers BJ
 
You could also incorporate a pedal sensor as well. If you hadn't already planned to do so. But at last someone is finally building an e-bike right. You may not be going to use the motors full power, but the option is there if you ever decide to use it.
 
Hi Neon,
Thanks for the suggestion of a pedal sensor as I hadn't thought of that. I will have to check and see if there would be any ill effects on my particular ESC by using this item.

Cheers BJ
 
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