Side mounted BLDC kit- on MTB

Hi Guys
Well its been a while since i posted on here...
after building many E-skates and scoots ive turned my hand to an Ebike-
I have KTM Macina (highly modified i might add )that i use to commute but i was also interested to see how a BLDC would perform ..(i had a lot lying around from my previous business)
So initially i wanted to try to use only 3D printed parts and i used my Road bike as a donor-
I used a 6374 motor,120a ESC and a 6s Lipo battery all in custom designed 3d housings and running a 15mm wide belt and pulley ..the battery is quick release that just slides out for charging..



I had to custom print a throttle for the drop as there are non on the market that fit ..


It achieved a nice 24mph with great hill climbing and only added around 2kgs to the bike weight- but i just couldn't live with e belt slippage ..

So i continued to use my Macina to commute and decided to change my design to fit the rear drop out
I initally tried all 3d printed clamp but i soon found out the 3d printed parts alone just didn't have the strength to clamp enough..
So I use a combination of waterjet parts and 3d printed inserts to suit the frame diameter ...and after several iterations its actually turned out pretty neat ,








The 3d printed gives the contour and the waterjet plates give the required clamp strength ..


The drive pulleys are from mini moto bikes and then a added to a waterjet ring that drives through the centre hubs ,where the spokes meet..works a treat



Using the same motor,esc and battery its achieves around 22mph on the fatter tires which was still good- and i have just added a 7s battery and this have significantly increased the top speed to around 26-27mph with very good torque- infact it will run at that speed with no pedaling..



I have printed flexible filament ESC holder with cable ties to the frame and now incorporated a BMS and charging port to the bottle battery..



so overall im happy with the results-
next step is to increase battery voltage to 8 or 10s ..then it will really fly !! make a full battery and esc enclosure and add a motor cover .. which im just protyping now..

Great design after some trial and error! Sub’d

Every time i think im going to build a regular bike, something like this always crosses my path and alters my thoughts!

yes- it took a few iterations but i was sort of doggedly set on only 3d printed parts..but soon realised a composite is better.. best of all worlds..
its really is a powerful yet lightweight system with massive scope for increased power..

It seems geared a bit tall. You might do better with a larger rear sprocket.

The belt drive looked good other than the idler should be on the bottom. But the belt was slipping? Seems like it should be possible to make the belt work as many full size motorcycles use belts.

no its geared just right ..no cogging from a standstill..i tried many size larger sprockets,,
on the chain drive the drive sprocket is only a 6t ..so allows a much smaller driven sprocket..

OK, as long as it's working for you that's the main thing. It seems like the no-load speed of the wheel would be super fast, but maybe the motor has a high enough kV to keep it in the right range.

its a 170kv motor- no load speed of wheel is just right..

Is that an air filter on the controller? :lol:

eerrrrmm...its called a heat sink... that's the technical term anyway...