E bike conversion with belt and pulley

by AlbertP, published

E bike conversion with belt and pulley by AlbertP Nov 17, 2017
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Update Jan 2018. After repeated attempts to get a belt driven ebike working and having at least 2 belts break, I have come to the conclusion that it's simply not worth it to go belt driven. Just get a hub motor and be done with all the headache and time wasted.

---------------OLD description below------------------

This is a parametric version of the pulley used in StatonFrames pulley. Now you can choose the number of spokes and locations of the zip ties and stuff for you specific bike.
The conversion is VERY finicky. I'd recommend printing out a profile test of the pulley before committing the plastic for a full pulley and check for fit. Be prepared to spent lots of time on this project.
I also redid the motor mount. I am actually not happy with it currently but I will post it and it might be okay for someone else. The plastic motor mount flexes too much and I switched to a metal motor mount with plastic clamps to mount to the frame tube. Will post pictures soon.
The motor mount was made in autodesk inventor. You'll need autodesk inventor if you want to change some parameters in that.
There's also a motor fan if you want to use that. It should improve motor cooling.

The hardware:

  • 4 x 2 1/4" 5/16 bolts OR M8 metric equivalent
  • 1 x 5/16 bolt for bearings (length depends on # of bearings used for idler)
  • 2-3 x 608 bearings
  • 5/16 washers and nuts
  • M4 bolts for motor (should come with motor)

Print Settings






0.3 or above




You'll want the motor mount at least 50% for strength. The pulley I printed at 25% and it seems to be okay for now ( after a few trial runs). Supports not required.

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Sad to hear you have given up on this project. Your anecdote about belts snapping is the first I've heard about this design. Are you sure that there isn't something else causing the snapping? Maybe a different supplier or quality of belt?

The belt was simply one of the factors. It was basically a PITA to have this all set up and I would have gotten a hub motor had I known this before hand. I'm working on a hub motor conversion which will be a lot more straightforward. I just finished making the battery for it.

Nice work!
I'd really appreciate it if you could upload a file that can be easily imported into Fusion 360! :D
Thanks in advance

I uploaded the step file, maybe that will help?

Whilst I am able to import it, it is everything but easy to work with.
Which CAD-Software do you use to create your designs?

I use autodesk inventor 2018. The source file is uploaded as an .ipt. Word of note thought, a belt driven ebike is not ideal. I would go for a hub motor and save yourself the headache. I only leave it here if people want to take on the challenge.

Ok, thanks for the advice!
I do actually plan to use a proper hub motor eventually when it arrives from China.
In the meantime I just wanted to try out my software and current motor setup.

This is the hub motor assembly:
I Plant to open it up and replace the ESC with a VESC.