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DIY Electric bike (motor mount & pulley)

by StantonFrames, published

DIY Electric bike (motor mount & pulley) by StantonFrames Mar 21, 2017
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Summary

Building a homemade electric bike using 3D printed parts! It was definitely a learning curve, but it worked out pretty well! https://youtu.be/9rIIJbDkpN8

If you would like to build the same setup, I have listed the parts required below. As mentioned in the video, I would really appreciate it if you purchased the parts via my affiliate links to support my work. Thanks!

Parts List
Bike: https://goo.gl/h2GIVm (UK)
https://goo.gl/MNdU2O (USA)
3D Printed parts:
Motor: https://goo.gl/3HFwXg
VESC: http://vedder.se/2015/01/vesc-open-source-esc/
Electric scooter throttle: https://goo.gl/yvloKG
Saddle bag: https://goo.gl/ilyxSJ
6s 5000mah li-po battery
HTD5 12T pulley (with 8mm bore for motor shaft)
HTD5 800x15mm belt
5pcs m4x30mm bolts (clamp motor mount to frame)
4pcs m4x10mm bolts (attach motor to mount)
1pcs m4x50mm bolt (roller bearings seat on this bolt)
5pcs m4 nyloc nuts
3pcs m3x10mm bolts (assembly of electronics case)
5mm wide cable ties (attach pulley to spokes)
EC5 battery connectors
4mm bullet connectors (for ESC)
Basic knowledge of electronics and soldering
and a 3D printer...

Also, the VESC is capable of using the electric scooter 'analog signal' and an input, so the arduino isn't required.

Note: The 3D printed brackets/pulley were designed specifically for the bike used in the video, it will not fit any other bike and I will not be modifying it on request to fit to other bikes.

Disclaimer: I do not hold responsibility for any wrongful riding if you chose to build this ebike. It is beyond the legal limit (250w) for an electric bike, which is why I chose to ride it within the grounds of my university.

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Great project!
I am going to build one myself. The Vesc is out of stock at hobbyking. Can anyone recommend another esc at hobbyking for the same motor?

Parametric Pulley Version

I've created a parametric version of the pulley used in this conversion and redid the motor mount to be stronger. Check out my thing https://www.thingiverse.com/thing:2651827

E bike conversion with belt and pulley
by AlbertP

Nice job. As you note, many parts are specific to this bike, and you don't plan on adapting to others... but how about some .f3d, .step, or any other format file that can cleanly be imported into fusion360 and edited... I'm sure more than 1 person will convert it for their bike, and share... which would likely drastically increase your audience (and I cannot stress how useful "Open Source" work will be, when you graduate and try to get a job... especially if your work is well known)

I've created a parametric version of the pulley used in this conversion and redid the motor mount to be stronger. Check out my thing https://www.thingiverse.com/thing:2651827

E bike conversion with belt and pulley
by AlbertP

Just fantastic ! thanks so much, really inspiring.

Please join a new group "Electric and Hybrid vehicles"

Hello, I am able to use this bike for my fixed bike and charge my mp4 or mobile phone jejejejejeje while I exercise.

Excuse me, what model is the motor, specific parameters???thanks

See "Thing Details", follow link next to "Motor".

Just wanted to say to anyone wanting to make the 'vesc' signal you require to feed to the speed controller is a standard RC PWM signal which can be easily generated by any cheap servo tester - so, no electronics knowledge is really required.
Just google "RC Servo Tester".
You would need to find a safe way to cobble it to the handlebars - with some 'deadmans handle' arranglement (don't even think about doing it without) - so maybe keep the electric bike grips.
Note also that the ESC will probably not 'arm' unless first supplied with a zero throttle at power-up, Some ESC's also require a 0% >25% - 0% "blip" of the throttle to arm.
Be safe - a motor this size could easily take a finger off.

Great project.

Hello, what did you smeared in the printer and how did you set the temperature of the table.

Pretty cool; have you considered adding a circuit to charge the battery when it detects voltage being generated motor when pedaling or coasting the bike?

Any update on the bike? parts failures, or anything similar?

It is a great project and I'd like to try it. The VESC though is more work than I'm willing to put into at this point given that I don't know enough yet. Can you recommend one that can be purchased outright that would work with the motor and throttle? Thanks

The 'vesc' signal you require to feed to the speed controller is a standard RC PWM signal which can be easily generated by any cheap servo tester - so, no electronics knowledge is really required.
Just google "RC Servo Tester".
You would need to find a safe way to cobble it to the handlebars - with some 'deadmans handle' arranglement (don't even think about doing it without) - so maybe keep the electric bike grips.
Note also that the ESC will probably not 'arm' unless first supplied with a zero throttle at power-up, Some ESC's also require a 0% >25% - 0% "blip" of the throttle to arm.
Be safe - a motor this size could easily take a finger off.

Would this work on any bike or just the one listed?

I havent tried this, but it should work with any bike you got, you might just need to make new mounts.

Would it be possible to get a 55XX version of the motor mount?

Comments deleted.

Is this kind of motor water resistant? So does rain matter? I wonder to see the copper ... do you have experience with this?

This is a brushless motor, and all brushless motors are waterproof. All other electronic components, ie. the speed controller, battery; are not waterproof. So, it's totally fine in the rain, as long as the speed controller and battery are sealed in some sort of container.

Can you post the cad Files too? I'd like to make some modifications

Im pretty sure you can convert the stl into a mesh, then convert that to b-rep

This motor is rated for almost 3.1kw, pretty impressive for something so light. Are there any commercially available Vesc's that you would recommend? I would like to try a more plug and play solution just to get one working and then maybe experiment with the open source stuff.

What type of filament?

He used pla, id say if you have the ability to, to use ABS, or something stronger, if you really want to do it right, nylon would probably be your best bet.

But pla should work for a while, unless its super hot out

In the video he mentions using PLA but is not sure about how well the plastic will perform under load, as PLA has a tendency to deform above 60C.

Can't thank you enough for making all of this readily available, awesome work Tom! Also, if you were going to print these parts again for another bike... Would you do the Motor fan for the turnigy 6374 again? Does the motor get any warmer without the fan?

Comments deleted.

How much would all the parts cost?

Nice, thank you Tom.
Does that motor bearings handle the side force from driving the belt? Cheers.

hi what cad & program did you use to create the pulley?

is there drag form the motor when you are pedaling?

brilliant ! thanks for sharing this gives me so many ideas

One of the coolest projects I've seen on Thingiverse yet! Great work and I can't wait to see more of your future designs and reiterations.

good project! i have the same motor for my electric kick scooter project (oxelo town 9) but is not easy... :-(
what's your max speed?

Hi nice video and build. Is it posible to scale down your pulley? And how do I do it? I am also making a diy project with four motors, but need a smaller pulley like yours. Thanks

Just saw your video, this is very cool. I'll be showing this to my kids. Thank you!

vesc can use analog signal directly

A thing of concern to me is that everything is open for water and dirt, how well do you think this fares when going home in the rain? Those lipo batteries are packing a mighty spark...

just close it in a 3d print box... i think you can DIY for real

I think weatherproofing a diy project like this is def possible as part of the next steps--but as I'm getting ready to spray rust inhibitor in my new frame, I'm wondering if it'd still involve a decent amt of r&d'ering..

Even with only riding it for longer but still partial day trips when rain/clouds aren't forecasted, and having it enclosed well enough to protect from random puddles and dust, there are still a lot of bump/vibrational forces that're going to be getting transmitted through the frame

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