Peter's custom bikes

Show off your E-bike creation here.
peters   100 W

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Peter's custom bikes

Post by peters » Jun 01 2013 10:44am

Hello people,
let me show a few drawings of my next bike, any opinion is welcome. This is a shed project, building has been started.
The frame will be one piece, the colors mean only that the orange parts are made of tubes and hollow sections, the yellow is sheet steel. The room for battery is large because I already have a pack of 29s headway 40152s.
Wheels are 24".

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Attachments
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b03.png
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b04.png
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b05.png
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b06.jpg
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Last edited by peters on Aug 31 2014 7:35am, edited 1 time in total.

peters   100 W

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Re: Peter's full custom bike

Post by peters » Jun 03 2013 12:52am

I'm learning to weld now and buying the parts for my TIG welder.
Last edited by peters on Jul 25 2013 1:08am, edited 1 time in total.

iamsofunny   100 W

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Re: Peter's full custom bike

Post by iamsofunny » Jun 06 2013 11:29pm

Welding is easy especially on steel. You need a lot of heat to get steel to flow nicely though.
Grease your bearings before you put them in or they'll rust and get stuck
make the rear disk mount adjustable or it'll drive you nuts trying to align it
check the roundness of the steer tube and bb shell when you weld
Looks good

peters   100 W

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Re: Peter's full custom bike

Post by peters » Jun 07 2013 12:00am

Thanks for the advice.

peters   100 W

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Re: Peter's full custom bike

Post by peters » Jun 20 2013 4:22am

learning to weld:
DSCN5817.JPG
Well, the head tube is not round any more, but the bearing still fits though.
The seat tube is temporarily welded to a piece of hollow section, otherwise it bent significantly at the top tube joint.

peters   100 W

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Location: Hungary

Re: Peter's full custom bike

Post by peters » Jul 02 2013 12:06pm

Some progress:
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I think it's not bad for a first frame build. It will look better after sandblasting.
Attachments
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05.jpg
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nicobie   10 MW

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Re: Peter's full custom bike

Post by nicobie » Jul 02 2013 12:09pm

It's looking good!
Image

May your tote always stay tight and your edge eversharp :wink:

my eTownie build thread: http://endless-sphere.com/forums/viewto ... =6&t=23701

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Ariane   10 kW

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Re: Peter's full custom bike

Post by Ariane » Jul 02 2013 12:49pm

Hi Peter,

I really love it nice job

Good day!
Black Arrow

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Samd   1.21 GW

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Re: Peter's full custom bike

Post by Samd » Jul 02 2013 3:14pm

+1 subscribed. Nice work.
http://ballaratebikes.com/

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"Knowledge is knowing that a tomato is a fruit. Wisdom is knowing that a 165mm rear shock can't deliver 220mm of rear swingarm travel." - Oprah Winfrey.

peters   100 W

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Location: Hungary

Re: Peter's full custom bike

Post by peters » Jul 11 2013 11:50pm

Thanks guys!
Some update: L-profile is welded on the left side around that will hold the side plate, and rear bracing is added. Still need to grind the corner welds. I decided to fabricate the rear fork of steel sheet instead of hollow sections, because it is a better way to make fine curves and corners.
frame06.jpg
A friend of mine cut the thread in the BB shell with his self-built CNC lathe:
cnc1.jpg
cnc2.jpg
cnc3.jpg

peters   100 W

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Re: Peter's full custom bike

Post by peters » Jul 25 2013 1:07am

Wheels:
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Cromotor, of course ;)

peters   100 W

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Re: Peter's full custom bike

Post by peters » Aug 31 2013 1:24am

Finished the frame welding in the last few days, some pictures of the swingarm fabrication:
swingarm.png
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DSCN5843.JPG
dropouts
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plots
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lower plate cut
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plates
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bent to shape
DSCN5869.JPG
welded
DSCN5873.JPG
welded and burnished
DSCN5942.JPG
finished

peters   100 W

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Re: Peter's full custom bike

Post by peters » Aug 31 2013 1:29am

The frame:
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peters   100 W

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Re: Peter's full custom bike

Post by peters » Aug 31 2013 1:40am

And the bike assembled. Wheelbase is around 1260mm, BB center height is 360mm (unloaded).
Next is to varnish the frame, then installing battery pack and circuits. I will ride soon :)
DSCN5956.JPG
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dingoEsride   100 kW

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Re: Peter's full custom bike

Post by dingoEsride » Aug 31 2013 1:48am

peters wrote:learning to weld:
You are a fast learner, great job
ride like the wind

peters   100 W

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Re: Peter's full custom bike

Post by peters » Aug 31 2013 1:51am

Thanks :)
Welding is really not that hard, but the difficulty is that after welding and cooling the shape and angles of the metal change due to the thermal expansion, and it can be several millimeters.
Last edited by peters on Aug 31 2013 2:39am, edited 1 time in total.

peters   100 W

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Re: Peter's full custom bike

Post by peters » Aug 31 2013 2:17am

That's me on the bike:
DSCN5968.JPG

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agniusm   10 MW

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Re: Peter's full custom bike

Post by agniusm » Aug 31 2013 2:43am

This is what I call finest of ES, fully custom self made bikes. Congrats on the frame. I like the swingarm a lot.

peters   100 W

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Location: Hungary

Re: Peter's full custom bike

Post by peters » Aug 31 2013 2:57am

Yeah, I got a lot of inspiration from here, from many people and designs and builds :)

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jansevr   1 kW

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Re: Peter's full custom bike

Post by jansevr » Aug 31 2013 4:08pm

what a great looking bike - very cool pictures too! and what a fast build especially considering you had to learn to weld! have you had a ride yet? whats the completed weight?

Sancho's Horse   1 kW

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Re: Peter's full custom bike

Post by Sancho's Horse » Aug 31 2013 5:14pm

Clean work.

kfong   1 MW

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Re: Peter's full custom bike

Post by kfong » Aug 31 2013 6:04pm

Nice metal work, do you have a final weight?

iamsofunny   100 W

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Re: Peter's full custom bike

Post by iamsofunny » Aug 31 2013 11:18pm

Very excellent work my friend

peters   100 W

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Location: Hungary

Re: Peter's full custom bike

Post by peters » Sep 01 2013 4:12am

Thanks for the comments. I pedaled just 20km, it is fine.
I cannot measure at the moment, but I expect the total weight around 45-48kg, including the batteries and electronics.

The frame front part is 9.9kg, the swingarm is 3.2, it is 13.1kg alltogether. It is heavy, but strong :).
It is made of 2mm thick steel sheet, because at the beginning I didn't have an idea about the strength and rigidity and I didn't want to risk. Now I see that 1.5 or 1.2mm sheet would be strong enough, maybe 1mm also, so 2/3 of this weight is easily achieavable. Maybe my next frame :)

Chuechco   10 mW

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Re: Peter's full custom bike

Post by Chuechco » Sep 02 2013 12:28pm

Hi, the frame looks great!
Do you have a special long bottom bracket so that the pedals don't touch the battery case?
How wide is the frame? Is it still confortable to pedal?

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