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E-Bike conversion

by stiganielsen, published

E-Bike conversion by stiganielsen Aug 3, 2016

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9230Views 497Downloads Found in Sport & Outdoors

Summary

The bike is converted to e-bike, and here are some drawings and references to where you can get the parts to do the same to your own bike. Of course you need to make sure all the parts will actually fit together and to your bike.

How I Designed This

How to do this

My bike has good disc-breaks - I strongly recommend you build this on a bike with good breaks. -And this design does not fulfil any regulations or traffic laws -so I take no responsibility for any other designs;)

You need tools:
Lasercutter for 5mm plexiglass min cutting size 350x350 mm
Metal tools for aluminium.. saw and drill only
zipties 3-5mm

You need to order or find:
---------------DC brushless motor: Turnigy Aerodrive SK3 5065 KV 236 a better choice would be one with lower KV ( for example Turnigy Aerodrive SK3 - 6374-192kv ) find it at hobbyking:
http://www.hobbyking.com/hobbyking/store/__522__517__Electric_Motors-45_to_50mm.html
------------alu pulley can be found at RS-components, but I have to get back on where to find this crucial component.
--------------Timing belt around 1380mm 5mm pitch: These should fit, but it depends on the dimensions of your bike too..
http://se.rs-online.com/web/c/pneumatics-hydraulics-power-transmission/power-transmission-belts/timing-belts/?sra=p#esid=4294957058&applied-dimensions=4293192670,4294771484,4294775939,4294883233
http://se.rs-online.com/web/p/timing-belts/4745886/
----------Motorcontroller:
Vesc is what I will install asap when I get it. I have found them here:
http://diyelectricskateboard.com/diy-electric-skateboard-kits-parts/vesc-the-best-electric-skateboard-esc/
You also need a form of servo tester for controlling that Vesc - you can also install a thumb gas controller- I haven't made that elegant yet, so here is where you can find a good (and safe) solution.

You need to cut your large timing pulley on a lasercutter. The files are here in the files section, but do modify the inner diameter to fit your bike axis somehow (the smallest circle in the drawing..) Bot inner circles in the has the 'spokes' cut out.. I just did that to have one pair slightly longer than the other pair because they tilt inwards along with the angle of the spokes, giving them longer distance to the inner pulley diameter.. -you just need the one pair of those 8 spoke pieces..

I used an angular piece of aluminium for mounting the motor to the 5mm alu plates that goes on the bike. These 5mm plates that mount on the bike are nice and easy to adjust when tighten and straighten the timing belt.

Not sure why image is turned 90degrees

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Hi !
No problem with the spokes ?

I'm making my E-bike and my original idea was to remove the rear disc brake and screwing my timing pulley on the disc. But I got an other idea : as i'm 3D printing my pulley, it would be possible to center the pulley inside the spokes and transmitting the power to the spokes directly.

But Is the transmission rigid enough between the large timing pulley and the wheel ? Ideally I would want no play, but is it possible ?

Im very glad if you share a DIY video supporting this please. :D

you got video of it working?

I do have a very short one:) I will try uploading it.. then I also want to make a little youtube diy video to support it

Looks awesome!!! How fast does it go?

40km/hour straight road no wind.. but only for about 20-30min

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