Building a custom e-bike frame

Show off your E-bike creation here.
User avatar
1800vtx   100 W

100 W
Posts: 103
Joined: Mar 03 2008 4:09pm
Location: Phoenix, AZ

Re: Building a custom e-bike frame

Post by 1800vtx » Oct 03 2009 1:10pm

Dude, you are truly one gifted fabricator..

Mucho impressed :mrgreen:
http://electric20inchfolder.blogspot.com
Downtube 9FS - 20" Folding/Dual Suspension
(Parts Arrived)
Crystalyte x5303 / 24-72V 35A Immediate Start Controller / Cycle Analyst - v2.11 Firmware / 9 Speed Freewheel
(Parts Coming When the Cash Flow Permits)
72V 15Ah Ping Pack, Shimano XTR Parts; Schlumpf High Speed Drive, Crankbrothers 5050 Pedal Set; Carbon Fiber Handlebar; Annodized Rims; Maxis Rubber

User avatar
voicecoils   10 MW

10 MW
Posts: 2096
Joined: Sep 16 2007 6:31am
Location: Sydney, NSW, Australia

Re: Building a custom e-bike frame

Post by voicecoils » Oct 05 2009 2:56am

Awesome, the enclosed chain looks quite nice.

Both your new project and Stealth Electric Bike's Stealth Fighter use the same 2 speed BB.

I've used it and it works well. It's a nice match for an ebike and the single speed driveline is nice and neat and doesn't slap around.

We'd love to see more details on the watercooling!

User avatar
dequinox   10 kW

10 kW
Posts: 867
Joined: Oct 31 2009 1:43pm
Location: Eugene, OR

Re: Building a custom e-bike frame

Post by dequinox » Nov 09 2009 12:50pm

:shock: Wow man, that is extremely awesome. You are one BAMF! Hopefully the acronym doesn't get me in trouble... :roll:
On a dusty pew in a vestibule sits the Devil playing pocket pool, he's waiting for the next poor fool who forgot that it was Sunday

STABLE:
HI-V (Retired); Sun Cruiser w/ Hill Topper Kit; Giant Simple Cruiser w/ Amazon 1000W Front Hub.
Parts donated by Rassy and Greenerwheels have made many of my builds possible, THANK YOU!!!

User avatar
AussieJester   100 GW

100 GW
Posts: 8736
Joined: Mar 11 2008 3:33am
Location: Perth Western Australia

Re: Building a custom e-bike frame

Post by AussieJester » Nov 09 2009 5:12pm

dequinox wrote::shock: Wow man, that is extremely awesome. You are one BAMF! Hopefully the acronym doesn't get me in trouble... :roll:
naaagh Hal knows hes a bad ass mother fucker as do the rest of us, he has L337 skills does our Hal ... Top job BTW mate
hows progress coming along? I think you have the hub boyz wet over your watercooled motor hehe get it wet..watercooled motor LoL.. :-P
What heat exchanger will you be using Hal? pc watercooling companies have a HEAP of nice size radiators that would be perfect for the job.
Thermochil being one of the most efficient radiators on the market (also the dearest) Laing mcp-355 pumps would be a great choice to circulate the water too..

KiM

User avatar
HAL9000v2.0   10 kW

10 kW
Posts: 974
Joined: Apr 14 2008 6:16am
Location: Zagreb, Croatia
Contact:

Re: Building a custom e-bike frame

Post by HAL9000v2.0 » Nov 10 2009 5:32pm

the liquid cooled hub is finished completly in theory. I am trying to find someone to make it. Kenny is not thrilled to do it. We will see... The motor is 8,5 kg and I hope it will have some 2kw cooling power so that means it can run constantly with 85% eff on some 13kw. It is fully modular so it can have small cooler with fan inside or it can be hosed on some bigger cooler outside. Plan is that swingarm get fins an become cooler...

Image

User avatar
AussieJester   100 GW

100 GW
Posts: 8736
Joined: Mar 11 2008 3:33am
Location: Perth Western Australia

Re: Building a custom e-bike frame

Post by AussieJester » Nov 10 2009 6:35pm

Very nice Hal, dunno about the swing arm working well as the heat exchanger though buddy
Personally i would LOVE too see a rad hanging off the front down tube and a lil pump circulating
the water, they draw fark all power i use two of them in my pc and 2 radiators too cool the CPU GPU and HDD :-P

You know what your doing though so i shall sit back in awe and watch it unfold :-)

Best of luck getting it build Hal ;-)

KiM

User avatar
Doctorbass   100 GW

100 GW
Posts: 7434
Joined: Apr 08 2007 2:24am
Location: Quebec, Canada East
Contact:

Re: Building a custom e-bike frame

Post by Doctorbass » Nov 10 2009 8:42pm

wow, what a nice job!!!

Great work Hal !!

Please can you show us more details about that desing?

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

markobetti   10 kW

10 kW
Posts: 620
Joined: Jul 17 2009 1:28am

Re: Building a custom e-bike frame

Post by markobetti » Nov 11 2009 4:55am

zakon hallllllllllll !!!!!!!!!!!!!!!!!!

svaka cast !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

User avatar
HAL9000v2.0   10 kW

10 kW
Posts: 974
Joined: Apr 14 2008 6:16am
Location: Zagreb, Croatia
Contact:

Re: Building a custom e-bike frame

Post by HAL9000v2.0 » Nov 28 2009 5:26pm

Here is something that I couldn't move along without. The notching machine. I made it out of single sheet of 8mm steel plate (1x2m).
-5 axis of freedom
-minimum angle is 8°
-for 19-80mm pipes
If anybody is interesting I can send him DXF for cutting pieces of puzzle.

Image
Image
Last edited by HAL9000v2.0 on Dec 05 2009 2:24am, edited 1 time in total.

User avatar
AussieJester   100 GW

100 GW
Posts: 8736
Joined: Mar 11 2008 3:33am
Location: Perth Western Australia

Re: Building a custom e-bike frame

Post by AussieJester » Nov 28 2009 7:30pm

REAL fabricators use an ANGLE GRINDER Hal :-P


Nice job mate very impressive ....wouldnt expect anything less from you though mate...still bet i could beat the machine
with my Metabo :mrgreen:

KiM

nuvola   10 mW

10 mW
Posts: 21
Joined: Nov 09 2009 6:11pm

Re: Building a custom e-bike frame

Post by nuvola » Dec 04 2009 8:00pm

where do you buy those disk brake(305mm)?
I was very impressed!
bike 1) 9C Rh205 28" Rear, controller 48V 27A with 51V 60ah battery, watt's up
bike 2) 5305 26" Rear, controller 72V 40A with 72V 15ah battery, CA

User avatar
liveforphysics   100 GW

100 GW
Posts: 14134
Joined: Oct 29 2008 1:48am
Location: Santa Cruz, CA, USA

Re: Building a custom e-bike frame

Post by liveforphysics » Dec 04 2009 10:31pm

What a nice tubing notcher! Damn! That would save me so much time making roll cages! It's so easy to mess up when you're trying to hand-grind tubes for 3 and 4 way intersections. I don't have the quality of trained beavers running my Metabo that KiM uses. :)
Each carcinogen vapor exposure includes a dice roll for cancer.

Each mutagen vapor exposure includes a dice roll for reproductive genetic defects in your children.

Each engine start sprays them into a shared atmosphere which includes beings not offered an opportunity to consent accepting these cancer experiences and defective genetics life experiences.

Every post is a free gift to the collective of minds composing the living bleeding edge of LEV development on our spaceship.

JEB   100 W

100 W
Posts: 287
Joined: Jul 19 2007 5:47pm
Location: Santa Barbara Ca

Re: Building a custom e-bike frame

Post by JEB » Dec 05 2009 1:47pm

Hi Hal; Very impressed by your build- if I might make a couple of suggestions- your data read-out box, I would have gone with the top and bottom al plates as you did, but with a inexpesive plastic spacer.

Using a wire welder, you could use a spatter off type material around the weld area to keep from having to clean up the weld spatter.

If you could a TIG welder you can make a more even weld- maybe Argon is too expensive?

User avatar
HAL9000v2.0   10 kW

10 kW
Posts: 974
Joined: Apr 14 2008 6:16am
Location: Zagreb, Croatia
Contact:

Re: Building a custom e-bike frame

Post by HAL9000v2.0 » Dec 05 2009 4:27pm

AJ: If you can do 100 tubes / hour I 'll install you. What the hel, I'll take you even at 1tube/hour, I bet you are more fun than this machine. ;)

nuvola: I made them. They can be instaled only on my custom hub 20mm axle with 90mm x 8 holes

live4fiziks: I can send you dxf. You can cut it on water-jet and it can came out realy cheap.

JEB: Actualy that case was part of a bet. The bet was that I can't make design just to cut it and bring home and fully assembled with max 5 pcs of tool that can fit in my pocket and wight less then 1/2 kg. I won the bet :)

User avatar
AussieJester   100 GW

100 GW
Posts: 8736
Joined: Mar 11 2008 3:33am
Location: Perth Western Australia

Re: Building a custom e-bike frame

Post by AussieJester » Dec 05 2009 6:11pm

HAL9000v2.0 wrote: I bet you are more fun than this machine. ;)
Maybe so Hal, but i would also drink all the beer in your fridge so i cost more to "run" hehehee...

tiz a top bit of gear mate very pro and for repetition work its a must have no doubt...

KiM

JEB   100 W

100 W
Posts: 287
Joined: Jul 19 2007 5:47pm
Location: Santa Barbara Ca

Re: Building a custom e-bike frame

Post by JEB » Dec 10 2009 3:15pm

Hal; Did you find a threaded bottom bracket? (1.37 X 24t) go to http://gaerlan.com (bike parts- tubing-)

auraslip   1.21 GW

1.21 GW
Posts: 3535
Joined: Mar 05 2010 5:19pm

Re: Building a custom e-bike frame

Post by auraslip » Mar 23 2010 4:11pm

Hey did you ever finish the canopy? I'm interested in one of these frames. They look beautiful and raw like an american sports car from the 70's.

Also what size SLAs are mounted in there? Did you find a more permanent mounting system besides bungee cords?

I can definitely see myself building one of these over buying a cheap motorcycle or car at the same price!
THANKS TO EVERYONE HERE WHO TAUGHT ME ABOUT EBIKES. I'M IN YOUR DEBT.

I sell Ebike Brake levers and throttles with custom connectors crimped on! $10 shipped!

ES facebook group

r/ebikes ebikes on reddit

auraslip   1.21 GW

1.21 GW
Posts: 3535
Joined: Mar 05 2010 5:19pm

Re: Building a custom e-bike frame

Post by auraslip » Apr 20 2010 6:26pm

Hey what do you all think about "soft tail" suspension systems?

It seems like it would be simple, light, and cheap.

Obviously not good for trail riding, but the 1 inch of play might be good enough for handling pot holes at +20 mph.

The moots ybb is made of titanium and costs as much as a small car.

Image

The salsa dos niner is ONLY $1000.

Image

Image

The KHS solo one was available as a soft tail in 2005 for $600. Chromoly too. I wish they still made it!

The cheapest I've found is a Schwinn midtown for $300 through costco.

Image

The frame geometry doesn't look good for mounting batteries.
THANKS TO EVERYONE HERE WHO TAUGHT ME ABOUT EBIKES. I'M IN YOUR DEBT.

I sell Ebike Brake levers and throttles with custom connectors crimped on! $10 shipped!

ES facebook group

r/ebikes ebikes on reddit

User avatar
HAL9000v2.0   10 kW

10 kW
Posts: 974
Joined: Apr 14 2008 6:16am
Location: Zagreb, Croatia
Contact:

Re: Building a custom e-bike frame

Post by HAL9000v2.0 » Apr 21 2010 6:57am

Somehow I miss some posts...
I am also nervous about canopy but the guy who is making them must do it on big machine an he will charge me nothing test series so that is why I don?t push him. I was pretty boring last week so he will maybe do something this week...
Max SLA is 6x12V15Ah but I wouldn't recomend it because it is allmost 25kg. Here is guy who fell of such greyborg.
Not serius, 2 stiches but the bike push him down the flor...
Image
softtail: There is allmost same amount of work as on regular DH swingarm so why do it? IMHO. CHECK THE PRICE ON TITANIUM :lol: Maybe is typo it should say Platinum? or even Lutetium?

User avatar
Accountant   10 W

10 W
Posts: 95
Joined: Apr 10 2010 11:16am
Location: Zagreb,Croatia,EU
Contact:

Re: Building a custom e-bike frame

Post by Accountant » Apr 25 2010 1:27pm

This is the guilty one:

Do not judge it too hard. It was a bit nervous in unexperienced hands.

Image

User avatar
j3tch1u   10 kW

10 kW
Posts: 695
Joined: Dec 26 2008 2:09pm
Location: Taipei, Taiwan

Re: Building a custom e-bike frame

Post by j3tch1u » Apr 25 2010 1:53pm

great engineering--functional and clean-looking. may i ask what diameter/thickness chromoly you used?

love the tube notcher. you could make $$ selling that. looks like you have some heavy machinery to bend those steel plates.

keep up the great work and thanks for sharing!

markobetti   10 kW

10 kW
Posts: 620
Joined: Jul 17 2009 1:28am

Re: Building a custom e-bike frame

Post by markobetti » Apr 26 2010 7:24am

i was riding it yesterday .. the bike is real good and no lifepo4 action there, but i totally changed opinion on lead acid ..... even with that much lead acid klio ,it still goes nicelly. Dont like the big front wheel anyway...

User avatar
AussieJester   100 GW

100 GW
Posts: 8736
Joined: Mar 11 2008 3:33am
Location: Perth Western Australia

Re: Building a custom e-bike frame

Post by AussieJester » Apr 26 2010 7:29am

markobetti wrote:i was riding it yesterday .. the bike is real good and no lifepo4 action there, but i totally changed opinion on lead acid ..... even with that much lead acid klio ,it still goes nicelly. ..
Hals frames are very nice, i have to say though the area
just two of those batteries take up you could fit enough lipo
to replace all the slas, just think of the range and weight saving if you filled the entire area with lipo :-| Great that your happy with the bike though, there is room for improvement in the future when time/money etc permit. Nice looking ride none the less :-)

KiM

patrickza   1 kW

1 kW
Posts: 465
Joined: Jul 06 2008 2:34pm

Re: Building a custom e-bike frame

Post by patrickza » Apr 26 2010 8:00am

What is the area of each compartment where there are 3 SLAs at the moment. I'd love a frame that could house 36 cellman 20ah cells in two groups of 18. Would they fit HAL? Otherwise how could I bribe you to make me a frame they would fit in?!
Greyb.org, Cromotor, Headway 83.2v 20AH, Lyen 18 fet: http://endless-sphere.com/forums/viewto ... =3&t=45514
Kona Kahuna, x5305, Headway 76.8v 10AH, Crystalyte 72v48A: http://endless-sphere.com/forums/viewto ... =3&t=10256
Bladez Scoot, 450W motor putting out 3kW, Headway 38.4v 10AH, Lyen special controller: http://endless-sphere.com/forums/viewto ... 35&t=25872

User avatar
HAL9000v2.0   10 kW

10 kW
Posts: 974
Joined: Apr 14 2008 6:16am
Location: Zagreb, Croatia
Contact:

Re: Building a custom e-bike frame

Post by HAL9000v2.0 » Apr 26 2010 8:19am

300x150x100mm or 300x150x120 with extra wide canopy.Two times and 230x150x100(120)mm where controller is.
I have at home some 20 and 15Ah and will try to arrange...
I 'll let you know.

Post Reply