Hi there.
Sorry my English I am from Switzerland.
I just finished my e-bike project. It did last longer than expected, but now it is finished and riding my bike really rocks.
The concept:
I just wanted a bike of my choice to be electrified. I did not want a front hub so I had to find another place for the battery than a rear rack because of the improper weight distribution. And I did not want to see much of the wiring. So the battery had to be somewhere in the bicycle frame. And in a case. I decided to buy an ezee-kit from http://www.ebikes.ca and so I did. Thanks to Justin at this place for all the answering on my noob-questions about electricity.
Then I bought a cannondale bad boy:
Before the bicycle was assembled by my dealer (I had to wait about 2 weeks) I just made an exact drawing from the frame geometry in my dealers shop. Cannondale would not give me a CAD drawing of the frame geometry. I asked.
Then I made an 1:1 Autocad drawing of the project (I am an architect. So no problems here):
Of course I verified the design in 3dsmax (what we do with all our projects). I had a low poly 3d model of another bike which I adapted to the original frame geometry. Good enough for an impression.
I then spent some time in fibreglass forums until I thought I knew enough. Then I started with modeling the form out of styrofoam (mainly used to insulate buildings).
Some priming & grinding:
View attachment 4
Epoxy over it so the separating agent would not destroy the styrofoam. Once again verifying the form...
I placed those strong inserts where the case will be connected to the bicycle frame. Just to be sure.
Put some separating agent on the thing. Ready to laminate:
View attachment 1
Laminating in process. I do not want to do this again. It's so toxic (endless-sphere?).
Sorry my English I am from Switzerland.
I just finished my e-bike project. It did last longer than expected, but now it is finished and riding my bike really rocks.
The concept:
I just wanted a bike of my choice to be electrified. I did not want a front hub so I had to find another place for the battery than a rear rack because of the improper weight distribution. And I did not want to see much of the wiring. So the battery had to be somewhere in the bicycle frame. And in a case. I decided to buy an ezee-kit from http://www.ebikes.ca and so I did. Thanks to Justin at this place for all the answering on my noob-questions about electricity.
Then I bought a cannondale bad boy:
Before the bicycle was assembled by my dealer (I had to wait about 2 weeks) I just made an exact drawing from the frame geometry in my dealers shop. Cannondale would not give me a CAD drawing of the frame geometry. I asked.
Then I made an 1:1 Autocad drawing of the project (I am an architect. So no problems here):
Of course I verified the design in 3dsmax (what we do with all our projects). I had a low poly 3d model of another bike which I adapted to the original frame geometry. Good enough for an impression.
I then spent some time in fibreglass forums until I thought I knew enough. Then I started with modeling the form out of styrofoam (mainly used to insulate buildings).
Some priming & grinding:
View attachment 4
Epoxy over it so the separating agent would not destroy the styrofoam. Once again verifying the form...
I placed those strong inserts where the case will be connected to the bicycle frame. Just to be sure.
Put some separating agent on the thing. Ready to laminate:
View attachment 1
Laminating in process. I do not want to do this again. It's so toxic (endless-sphere?).