Carbon ebike - Casey

Abez · Oct 19, 2013

Hi everyone!
A year ago, I began to build the project Casey - carbon handmade or sixto elemento electric bicycle:

Handmade carbon frame, 29er wheels, single-stage timing belt to the motor, Mini-e controller, RC motor - RotoMax 50cc, 8-speed hub to the pedals...
Now frame looks like this:

More photos can be found here
Topic from the beginning on the Russian forum

spinningmagnets · Oct 19, 2013

Very nice work! I look forward to seeing the finished product...

silvocross · Oct 20, 2013

Really nice! How did you created the tubes?

APPELBOOM · Oct 20, 2013

Wow, awesome!

Never heard of that controller though... interesting!

Abez · Oct 20, 2013

Thanks!

silvocross said:
How did you created the tubes?

Simple geometric tubes:

And others from foam AIREX S70.55 make the shape tubes:

and next carbon plus epoxy:

APPELBOOM said:
Never heard of that controller though... interesting!

http://endless-sphere.com/forums/viewtopic.php?f=3&t=37377

LSBW · Oct 20, 2013

Молодец, хороший проект!

Good job, buddy!

Whiplash · Oct 20, 2013

Wow! Awesome work!! Looking great! I wish I had carbon skills!

Abez · Dec 4, 2013

All elements of the puzzle:

Now start the assembly:

oatnet · Dec 4, 2013

Very interesting, I look forward to seeing where you take this!

-JD

Byte · Dec 4, 2013

This could get to be the most fascinating build of 2014... A light carbon bike with a light yet powerful rc motor. Awesome! I'm very excited about the end result!

Abez · Dec 8, 2013

All the pieces are assembled. And here is the result:

And now it is necessary to master the process of vacuum infusion.

kfong · Dec 8, 2013

Cool carbon work. I'll have to give it a try. A drift trike sounds like a good way to practice. Keep the photos coming!

Abez · Jan 28, 2014

First carbon layers:

Further align the surface with a putty and the last layer of carbon:

spinningmagnets · Jan 28, 2014

It's good that you are taking lots of pictures of the entire process...someone might want to write an article about this!

Abez · Apr 3, 2014

Participated in two exhibitions. The first 20 miles on the pedals, and then 90 miles with PAS (hub motor-350W put to the test).

Abez · Apr 3, 2014

On the bike will only rear fender.
Attach to the wheel four milimeters foam:

A thin layer of fiberglass:

Gave it couple coats of mold release wax. Next I laminated two layers of carbon fiber 2x2 twill, and several layers of cling film on top :

Proxxon fix to the plate and cut off all unnecessary:

P.S. I started to write an article. It now remains to complete the project and translate the article into English.

Kmob1 · Apr 3, 2014

Great project mate, look forward to seeing your final product and it's weight

liveforphysics · Apr 3, 2014

I'm extremely impressed!!! Wow!! This is one of the nicest DIY frame builds we've ever seen on ES! Outstanding work! Thank you for sharing!

corbretti · Apr 3, 2014

Truly outstanding and innovative..Thank you for sharing..This is by far my fav build..Modern technology on old school racer looks..

byebyepetrol · Apr 3, 2014

Thanks for the photos especially the mudguards.

Mind if I "borrow" your idea? I need to make a front guard for my bike

Love your cutting rig!

Chris.

Abez · Apr 4, 2014

Thank you very much for your kind words!

byebyepetrol said:
Mind if I "borrow" your idea? I need to make a front guard for my bike
Chris.

Do not mind, use.
To reduce the cost you can use the same weave fiberglass instead of carbon fiber:

4760d1256766183t-hexcel-texalium-fiberglass-cloth-hex.jpg

Arbol · Apr 4, 2014

I subscribe myself here, thanks!

I am interested in reading more about the carbon fiber construction, as well as the usage of RC motors. Looking forward to read your article.

Voltron · Apr 4, 2014

It's a great looking build... and totally not being the naysayer, but the headtube to downtube join is a little worrisome. It seems like with all the stress there esp with the added weight of the drive package having a stub tube of carbon coming off the headtube for the downtube to mold around, or some extra wraps of cloth around the actual head tube... it seems like its mostly counting on the adhesive bond the way is?

Ch00paKabrA · Apr 4, 2014

Wow! Awesome build. You have skills!

Thank you for sharing this with us.

I can't wait to see the finished product.

Abez · Apr 11, 2014

Voltron said:
It's a great looking build... and totally not being the naysayer, but the headtube to downtube join is a little worrisome. It seems like with all the stress there esp with the added weight of the drive package having a stub tube of carbon coming off the headtube for the downtube to mold around, or some extra wraps of cloth around the actual head tube... it seems like its mostly counting on the adhesive bond the way is?

In the area of headtube to downtube join - all okay, all carbon layers from downtube go to headtube. But bottom bracket tube with battery box join need to do something. It was the most difficult join, it is necessary to consider how to strengthen.

Carbon ebike - Casey

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