Very DIY Street Legal 48v 2kw

[not.py]

Welcome, to start a few months ago I had my very illegal 70mph e-moto seized you can read more about that here
Our legal e-bikes in the UK are called an EAPC (Electrically Assisted Pedal Cycle), you will see them referenced as this through out my post.
The plan:
A "street legal" e-cycle abusing every loophole there is to maximise power. I've read our rules a countless amount of time to verify the legality of what I am attempting.

"Loopholes":
Generally all EAPCs are pedal assist. The law states:
"Pedal cycles providing electrical assistance without use of the pedals, usually called ‘Twist and Go’" ... Are illegal.
As you can see it rules out power without use of pedals, meaning if you pedal very slowly you are allowed to use a throttle but only when pedalling.

EAPCs are also limited to a maximum of 15mph before assistance needs to cut out. Temporary switches for this are also in violation.
"Some electric cycles offer a temporary increase in top speed that is often advertised as ‘off road’ mode. When ‘off road’ mode is activated, the vehicle can be propelled by the motor at a speed greater than 15.5 mph.
Vehicles that have this feature do not, in our opinion, comply with the EAPC regulations and are considered motor vehicles."
Now, I'm fine with everything but this rule. I believe being restricted to 15mph is dangerous.
To bypass this I am using a very overcomplicated hidden "switch", This is a remote key fob that will be hidden under my coat as well as a lanyard.
In simple terms when the lanyard is disconnected the key status resets to off.
To turn back on you need to keep the lanyard on and tap the key fob.
At a stop you would simply pull the lanyard off or even just get off the bike as a whole, if the officer gets suspicious and attempts to put the lanyard back it will also require the key button to do anything. This is the only illegal part on this build.


We are also limited to a 250w continuous motor:
"have an electric motor with a maximum continuous rated power not exceeding 250 watts "
This is a very vague rule. To my understanding all manufacturers rate "continuous" differently.
There isn't much we are bypassing here, just pushing 2kw peak through a cheap 250w continuous motor.

The guidelines also allow for these bikes to have a "Walk Assist Mode"
"‘Walk assist’ functionality (where the speed doesn’t go above 3.7 mph) is outside the scope of type approval."
This means that I can get going up to 3.7mph before the pedal sensor kicks in.



Loopholes out of the way, onto the fun part.

Custom Stark Varg Style Phone Holder
I love how easy it is to slip your phone in and out of this holder that I made a "clone" of it using Fusion 360.
This is still in the works but i do have the mechanism completed so far.

This is one of many prototypes and is still a WIP. The main frame of the phone case was for testing and demonstration, it will NOT look like that in the final version.

Mechanism Photos:

Hard to show in images
So far the mechanism is done and it works well. Holds my phone solid with enough spring pressure to not be an issue.


Stark Varg Style Display (Yes, Another thing copied from the varg)
If you are unaware the Stark Varg's display is a phone app, I love this as it lets me see notifications, use maps and have my phone center screen while being able to log everything important. I am in the process of making my own version of this using a Raspberry Pi Zero 2W as the main computer casting a display to my phone. I'm still looking into the best ways to do this but I have some ideas.
The functionality of reading and decrypting data being sent from my Fardriver's BLE Module is all done and ready for this.


Theory done. Here is the bike Im using for this project:

As you can see it is a full suspension, I picked it up used for not too much a bit ago and started the conversion by putting my old bag on it and attaching the battery mounting plate.
This battery is a 48V 13AH that has ~2000 miles on it since new (Its been through a few of my bikes). The same style as the one below.


The controller I'm using is a Fardriver 72v 50a bought directly from lvchao@far-driver.com once again.
This was a grand total of £75 ($98), I'm pretty sure this is the cheapest you will find it.
I've attached it inside of the bag with 2 custom frame clamps:
(More pics of it on the bike coming soon)
I wrapped a small cut of old innertube around the clamp and frame to make sure it fits well. To what I've seen so far its holding solid but I have yet to test ride.


For the motor, I picked up a bunch of used 250w Bafang motors from ebay and facebook that need fixing. Currently looking at re-spoking a Bafang G310 (I think) onto a 27.5 inch rim.


Main Speed Controller

That is a Raspberry Pi Zero 2W, A Keyfob Receiver, And 48v to 5v & 12v Converters.
There is also a buzzer for when boot is done or errors as well as a small transistor tucked away for mode switching.
All of this together reads PAS Signals, Hosts a dashboard and swaps Fardriver 3 speed modes depending on pedalling/limited status.

This has been a very interesting project so far and I'm looking forward to completing it. We are currently awaiting spokes and various other little parts to get the motor running.
Thank you for reading, please leave a comment with your thoughts. Sorry if this isn't the best writing its been a minute.

 

[Risky Rob]

I've read that in Europe, certain jurisdictions will actually test a suspect bike on a dynamometer. Will your mods be accepted?
In California, the law in January changed to 750W maximum. I should have scrapped my 1500W hub motor, but feel it's enough that I never exceed the maximum speed of 28 mph. That satisfies the spirit of the law.

 

[not.py]

I've read that in Europe, certain jurisdictions will actually test a suspect bike on a dynamometer. Will your mods be accepted?
In California, the law in January changed to 750W maximum. I should have scrapped my 1500W hub motor, but feel it's enough that I never exceed the maximum speed of 28 mph.

The UK doesn't have the equipment for that currently but yes it would. The only things that will affect that is wattage and speed limit, my speed limit switch would be impossible to enable on a dynamometer so it would be limited to 15 (The limit) and 2kw is perfectly legal as long as the motor is rated for 250w constant (It is).
There have been attempts to raise the limit to 500w in the past but sadly non were successful.

 

[neptronix]

Love your solution, interested in seeing how things go for you.

My current best cheat is to have a huge chainring and pedal the whole time. My bikes also maintain a bike-like appearance as much as possible, which i think you're nailing.

What motor is on that thing?

 

[not.py]

What motor is on that thing?

I think we are going to use a Bafang G310, it's not on the bike yet as described in the last paragraph though. The photo there only has the bag, battery plate and handle bar things although everything will be packed inside the bag so it shouldn't look much different.

 

[Papa]

What was the $ value of the confiscated bike?

 

[not.py]

Check my old post linked at the top for more details, I think it came out to about £1k/$1.3k

 

[not.py]

Still a long way off but i would love to turn my fardriver display app prototype into a open source project that allows people to design there own displays or clone the look of existing ones that are not compatible with the fardriver.
Previously i was using GDriver but there display really isn't optimal for what i want and a sandbox style custom display builder would be super nice.

 

[E-HP]

Welcome, to start a few months ago I had my very illegal 70mph e-moto seized you can read more about that here
Our legal e-bikes in the UK are called an EAPC (Electrically Assisted Pedal Cycle), you will see them referenced as this through out my post.
The plan:
A "street legal" e-cycle abusing every loophole there is to maximise power. I've read our rules a countless amount of time to verify the legality of what I am attempting.

"Loopholes":
Generally all EAPCs are pedal assist. The law states:
"Pedal cycles providing electrical assistance without use of the pedals, usually called ‘Twist and Go’" ... Are illegal.
As you can see it rules out power without use of pedals, meaning if you pedal very slowly you are allowed to use a throttle but only when pedalling.

EAPCs are also limited to a maximum of 15mph before assistance needs to cut out. Temporary switches for this are also in violation.
"Some electric cycles offer a temporary increase in top speed that is often advertised as ‘off road’ mode. When ‘off road’ mode is activated, the vehicle can be propelled by the motor at a speed greater than 15.5 mph.
Vehicles that have this feature do not, in our opinion, comply with the EAPC regulations and are considered motor vehicles."
Now, I'm fine with everything but this rule. I believe being restricted to 15mph is dangerous.
To bypass this I am using a very overcomplicated hidden "switch", This is a remote key fob that will be hidden under my coat as well as a lanyard.
In simple terms when the lanyard is disconnected the key status resets to off.
To turn back on you need to keep the lanyard on and tap the key fob.
At a stop you would simply pull the lanyard off or even just get off the bike as a whole, if the officer gets suspicious and attempts to put the lanyard back it will also require the key button to do anything. This is the only illegal part on this build.


We are also limited to a 250w continuous motor:
"have an electric motor with a maximum continuous rated power not exceeding 250 watts "
This is a very vague rule. To my understanding all manufacturers rate "continuous" differently.
There isn't much we are bypassing here, just pushing 2kw peak through a cheap 250w continuous motor.

The guidelines also allow for these bikes to have a "Walk Assist Mode"
"‘Walk assist’ functionality (where the speed doesn’t go above 3.7 mph) is outside the scope of type approval."
This means that I can get going up to 3.7mph before the pedal sensor kicks in.



Loopholes out of the way, onto the fun part.

Custom Stark Varg Style Phone Holder
I love how easy it is to slip your phone in and out of this holder that I made a "clone" of it using Fusion 360.
This is still in the works but i do have the mechanism completed so far.
View attachment 381099View attachment 381100View attachment 381101
This is one of many prototypes and is still a WIP. The main frame of the phone case was for testing and demonstration, it will NOT look like that in the final version.

Mechanism Photos:
View attachment 381102View attachment 381104
Hard to show in images
So far the mechanism is done and it works well. Holds my phone solid with enough spring pressure to not be an issue.


Stark Varg Style Display (Yes, Another thing copied from the varg)
If you are unaware the Stark Varg's display is a phone app, I love this as it lets me see notifications, use maps and have my phone center screen while being able to log everything important. I am in the process of making my own version of this using a Raspberry Pi Zero 2W as the main computer casting a display to my phone. I'm still looking into the best ways to do this but I have some ideas.
The functionality of reading and decrypting data being sent from my Fardriver's BLE Module is all done and ready for this.


Theory done. Here is the bike Im using for this project:
View attachment 381105
As you can see it is a full suspension, I picked it up used for not too much a bit ago and started the conversion by putting my old bag on it and attaching the battery mounting plate.
This battery is a 48V 13AH that has ~2000 miles on it since new (Its been through a few of my bikes). The same style as the one below.
View attachment 381106

The controller I'm using is a Fardriver 72v 50a bought directly from lvchao@far-driver.com once again.
This was a grand total of £75 ($98), I'm pretty sure this is the cheapest you will find it.
I've attached it inside of the bag with 2 custom frame clamps:View attachment 381107
(More pics of it on the bike coming soon)
I wrapped a small cut of old innertube around the clamp and frame to make sure it fits well. To what I've seen so far its holding solid but I have yet to test ride.


For the motor, I picked up a bunch of used 250w Bafang motors from ebay and facebook that need fixing. Currently looking at re-spoking a Bafang G310 (I think) onto a 27.5 inch rim.


Main Speed Controller
View attachment 381109
That is a Raspberry Pi Zero 2W, A Keyfob Receiver, And 48v to 5v & 12v Converters.
There is also a buzzer for when boot is done or errors as well as a small transistor tucked away for mode switching.
All of this together reads PAS Signals, Hosts a dashboard and swaps Fardriver 3 speed modes depending on pedalling/limited status.

This has been a very interesting project so far and I'm looking forward to completing it. We are currently awaiting spokes and various other little parts to get the motor running.
Thank you for reading, please leave a comment with your thoughts. Sorry if this isn't the best writing it’s been a minute.

Are you reviewing non ebike laws as well? The funny thing about the law, vs a law, is that the law is broad. You’d want to avoid committing a more serious crime when trying to avoid something that may be a minor infraction. I’m not familiar with UK laws, but you’d want to know whether your hidden switches can be used as evidence for something else and not specific to ebikes, like attempting or planning to commit a crime, etc. you might consider whether this thread itself, if discovered, could be construed or used as evidence of conspiracy by including others in your planning, etc.
May sound far fetched, and I’m not a lawyer, but worked with enough of them to know not to focus too narrowly. You don’t want to end up as the example in court.

 

[not.py]

you might consider whether this thread itself, if discovered, could be construed or used as evidence of conspiracy by including others in your planning, etc.

If law enforcement see this thread, track me down, alert local officers who then obtain a warrant to enter my house I am willing to call that fair game.

 

[E-HP]

If law enforcement see this thread, track me down, alert local officers who then obtain a warrant to enter my house I am willing to call that fair game.

But it seems like they might not have anything better to do. It must be nice to have so little crime that the cops have time to go after e-bikes, so I guess that’s the upside to living in the UK. Just riding responsibly around cops is usually good enough in a lot of places.

 

[not.py]

But it seems like they might not have anything better to do. It must be nice to have so little crime that the cops have time to go after e-bikes, so I guess that’s the upside to living in the UK. Just riding responsibly around cops is usually good enough in a lot of places.

Oh no, there is crime. A lot of it.
It's actually the other way around, there is so much uncared about crime that they go after e-bikes.

 

[E-HP]

Oh no, there is crime. A lot of it.
It's actually the other way around, there is so much uncared about crime that they go after e-bikes.

It costs more to go after criminals, especially if they catch and have to jail them. Most ebike owners will pay the fines and not take up jail space. Much higher net revenue for the local government. If your bike ever gets stolen, it’s better if they don’t go after the thief, for the budget at least. Solid business model.

 

[dankschikd]

Still a long way off but i would love to turn my fardriver display app prototype into a open source project that allows people to design there own displays or clone the look of existing ones that are not compatible with the fardriver.
Previously i was using GDriver but there display really isn't optimal for what i want and a sandbox style custom display builder would be super nice.

hey dood,

cool to see your project, sounds like a lot of fun. i am thinking of building my own custom ebike and found out about this website and saw your thread, i hope your project has gone well so far. i'm imagining a fat tire like a mokwheel basalt or aventon aventure that remains legal within my jurisdiction with maybe a lil overspec (~28mph max)

i'm interested to see youve got the idea to use a raspberry pi because i was also thinking of using a raspberry pi to do some unique things. firstly, itll be a hybrid controller for a hybrid battery+supercapacitor system which i kind of recommend for your goal of legal gray area lol exactly what is the wattage of a capacitive boost or regenerative impulse?

i'm particularly interested in building a hybrid supercap+battery system for other reasons; it lengthens the lifespan of the battery by absorbing/tuning surge currents, it performs better in cold weather, and you get regenerative braking because lithium banks cant charge fast enough for that but supercaps can.

additionally, i wanna use a raspberry pi because i want to have preloaded offline maps/routes on it for touring areas with no signal and i kinda wanna be able to play pixel dungeon on it lmao

anyway, godspeed in your journeys m8

 

[n00b]

I've read that in Europe, certain jurisdictions will actually test a suspect bike on a dynamometer. Will your mods be accepted?
In California, the law in January changed to 750W maximum. I should have scrapped my 1500W hub motor, but feel it's enough that I never exceed the maximum speed of 28 mph. That satisfies the spirit of the law.

I'm runnin' around with a 72v battery and a 2K motor at around 41 mph.
They don't mess with us here much. Need to get brake pads for that one. Front brakes are gone, the ones that do the real stopping. Might have one around the pads could be cannibalized off of.
It must have the good pads. Those are the ones that wear out quick. They stop better, too.

 

[n00b]

It costs more to go after criminals, especially if they catch and have to jail them. Most ebike owners will pay the fines and not take up jail space. Much higher net revenue for the local government. If your bike ever gets stolen, it’s better if they don’t go after the thief, for the budget at least. Solid business model.

They hit the low hanging fruit, aye?

 

[n00b]

But it seems like they might not have anything better to do. It must be nice to have so little crime that the cops have time to go after e-bikes, so I guess that’s the upside to living in the UK. Just riding responsibly around cops is usually good enough in a lot of places.

I have ridden by cops on an e-bike and they said "thank you", and so did random people all along the way, and I thought that was weird. I mean, I'm polite with people, I don't go bombing past crowds where somebody could be hit.
But this was weird to me.