My scratch built left-side drive hill climbing cruiser

ElliottE

100 mW
Joined
Apr 27, 2012
Messages
36
Location
Spokane, WA
Back in Spring of 2012 I decided to design and build a comfortable cruiser that could pull me (at 238 lbs) up the steep hills of my hometown, Spokane. Furthermore, it had to have the range to get me all the way across town and back, while handling said hills. After multiple design revisions and two prototype designs, I now have prototype #2 in hand and ready to show off to the world. This bicycle was built from raw tubing, sheet metal and various components.

This design has been performing very well, I've been taking it out daily since last week and getting in 20+ mile rides on it, with lots of hills along the way. The top speed is 20 mph, I have it governed to max out at 1000 watts output, it weighs 84 pounds and is extremely comfortable to ride; when I get off the bike I'm not sore at all, something I cannot say for most bicycles.

This design handles all but the steepest hills entirely under motor power, when the hills get steep enough to bog the motor I add pedal assist. I'm able to climb the very steepest hills I've encountered so far at about 10mph while pedaling along in 4th gear, and I'm not having to stand on the pedals, the additional effort I'm putting into the crank is roughly equivalent to what I'd be putting into the pedals while pedaling up a very modest incline without a motor. I'm very happy with the Shumaker drivetrain that I've been using in these prototypes, and the Cycle Analyst V3 is performing extremely well along with the Castle Creations controller, and last but not least the Allcell 36V 20Ah battery has been performing to spec, I've gotten 18Ah out of it in one 25 mile ride and it was still going strong.

Special thanks to Glenn Copus of Elephant Bikes for his guidance and insight during this design process. Additional thanks to Matt Shumaker, and a special thank you to the good people at Grin Cyclery who make the Cycle Analyst.
 

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Here's some pics from the building process.

Frame Jig 1.jpg
Frame jig, made from laser cut steel and a solid-core door

Cutting Miters.jpg
Cutting miters on tubing

Front Triangle in progress.jpg
Front triangle in jig

Front Triangle with mill.jpg
Front triangle, with mill, welding rig, saw and tube bender in background

Frame with mount rings.jpg
Frame all welded together

Inside enclosure 2.jpg
Inside the enclosure after assembly
 
Wow, another Spokanite. Great job. I really like the way it turned out. We should get together for a ride sometime.
 
I took this video today on my e-bike, climbing a very steep hill here in Spokane.

http://youtu.be/Aniph7bn9CA
 
Here's a Hyperlapse video I did today on prototype #2. The ride covered 25.2 miles, including over 1000 feet of climb, with a combined weight of 240 pounds between the rider and the cargo in the saddlebags. This ride used 16.3 Ah of battery out of what appears to be roughly 19.3 Ah of capacity in my Allcell 36V 20Ah battery.

https://www.youtube.com/watch?v=RxZehw5vGXw
 
Cool video. Surprisingly steady. Looks like a nice ride. :)
 
I've launched a Kickstarter campaign to raise funds for continued development of my e-bike design. Here's the URL:

https://www.kickstarter.com/projects/2021742949/a-high-performance-hill-climbing-e-bike-from-surge

I invite all of you to take a look, and consider contributing and/or letting your friends know about this project.
 
Went on a nice 20-mile ride with Mark today, here's a pic of our e-bikes.

Two E-bikes v2.jpg

Mark did an excellent job on his e-bike, the craftsmanship on it in person is really impressive.
 
Thanks Elliott. That was a great ride. It was fun to compare the two different drive approaches. Your bike was fantastic to see. It turned out great. Love the style! Thanks for the opportunity.
 
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