Otis Singleton
Electric bikes have become increasingly popular, especially since the pandemic, as they provide an alternative way of commuting. Building your own electric bike is a challenging but rewarding project. It can be done for under $100 if you have the right tools and knowledge, or for under $500 with an electric bike conversion kit. The process is simple and easy with the right kit, and you can even customise it with LED lights. However, it is important to consider safety, especially when adding an electric bike kit to a low-quality bicycle.
| Characteristics | Values |
|---|---|
| Budget | $600-1000 |
| Battery | Sealed lead-acid battery, BBSHD, 52-volt, 1500-watt, 110v |
| Motor | 500-750W, 1500W, 1000W |
| Top Speed | 36mph |
| Range | 25-35 miles per charge |
| Wheels | Front-wheel, rear-wheel |
| Kit | Conversion kit, pre-built kit |
| Additional Parts | Torque arm, 42T off-set chainring, 12-50T cassette 9 speed with a 10 to 12-speed derailleur, 9-speed gear |
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What You'll Learn
Sourcing a bike and kit
Buying a New Bike
If you are buying a new bike, it is important to consider the type of bike that is suitable for you. The type of bike you choose will depend on your unique needs, interests, and expectations. For example, if you are a mountain biker, you will need a mountain bike, while if you are a casual road biker, a standard road bike will suffice. You should also consider the size of the bike and ensure that it fits you properly. The frame size you choose will depend on your height. Additionally, the material of the frame is important, with carbon, aluminium, and steel being common options, each with its own advantages and disadvantages.
Converting an Old Bike
If you are converting an old bike, you can either use an existing bike that you own or source a second-hand bike. It is important to ensure that the bike is in good condition and has been well-maintained. You will also need to consider the type and size of the bike, as different conversion kits may be more or less suitable for different types and sizes of bikes.
Choosing a Conversion Kit
There are several factors to consider when choosing a conversion kit. Firstly, you need to ensure that the kit is compatible with your bike. This includes considering the size of the bike, the type of motor, and the voltage and output of the battery. You should also check whether the kit includes a battery, as not all kits do. The battery is typically the biggest ongoing expense in owning an electric bike, so this is an important consideration.
Some popular conversion kits include the Bafang mid-drive system, the TongSheng mid-drive motor, the Voilamart rear wheel conversion kit, and the Rubbee X wireless conversion kit. These kits vary in terms of their weight, power output, torque, compatibility with different bike designs, and ease of installation. It is important to research different kits and choose one that best suits your needs and budget.
Additional Considerations
When sourcing a bike and kit, it is important to consider your budget and the level of difficulty you are comfortable with. Building an electric bike can range from very affordable to quite expensive, depending on the quality of the bike and kit you choose. Additionally, some kits may be more difficult to install than others, so it is important to assess your level of technical skill and comfort with electrical work.
In conclusion, sourcing a bike and kit is the first step in building your own electric bike. It is important to consider your needs, budget, and technical skills when making your choices. With the right research and planning, you can successfully source a bike and kit that will allow you to build the electric bike of your choice.
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Installing the motor
First, decide on the type of motor you want to install. There are two main types of electric bike conversion kits available: mid-drive and hub motors. Hub motors are more common and can be installed on the front or rear wheel, while mid-drive motors are located in the middle of the bike and tend to be more expensive. The type of motor you choose will determine the installation process, so it's important to read the instructions that come with your kit carefully.
Once you have your motor kit, it's time to start the installation process. If you're installing a hub motor, the first step is usually to remove the rear wheel. To do this, loosen the brake cable and the wheel's quick-release lever. Hold down the rear derailleur while lifting the wheel to remove it. You may need to use a freewheel remover tool and a socket to remove the freewheel. If you're reusing your tire and tube, use tire levers to remove them from the old wheel and transfer them to the new one.
Now, it's time to install the motor itself. Follow the instructions provided with your kit for mounting the engine. Make sure to torque the bolts in a star-shaped pattern and ensure good tension on the bicycle chain. If your frame requires compensation for a larger downtube or seat tube, you may need to remove the motor mount studs and use u-mounts or vibration motor mounts. Don't forget to install the clutch and adjust the clutch cable as per the manufacturer's instructions.
The next step is to connect the electrical wiring. Your electric wiring will typically include the magneto, CDI, kill switch, and spark plug. The kill switch and spark plug are usually already installed. Connect the CDI to the magneto and kill switch using the colour-coded wires. Ensure you have additional stopping power with caliper or disc brakes, even if your wheel has a coaster brake.
Finally, it's time to test your setup. Install the appropriate software or drivers on your PC and connect the cable to run the configuration software. Adjust the settings to your preference, including max speed, acceleration, and regenerative braking. Test your electric bike on a short ride, ensuring compliance with local laws and safety regulations.
Building an electric bike can be a rewarding project, but it's important to approach it with careful planning and attention to detail. Always refer to the specific instructions provided with your chosen motor kit, and don't be afraid to seek guidance from experienced builders or professionals if needed.
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Attaching the battery
When it comes to attaching the battery to your electric bike, there are several options to consider. Firstly, it's important to note that the battery is often the most expensive part of an electric bike system, so you'll want to ensure it's secure and easily portable. One popular method is to use a backpack battery, which ensures you never forget to take the battery with you when you park your bike, and also provides a quick solution to disconnecting the battery in case of emergencies.
Another option is to utilise a heavy-duty welded-on rack for the battery. While this option may not distribute weight in the ideal location, it is a secure method that ensures the battery won't come loose. If you're looking for a more central weight distribution, consider using a triangle bag, which can be attached to the large triangle space typically found on hard-tail frames. This option offers a range of affordable choices.
For those seeking a more stealthy approach, a "water bottle battery" can be attached to a frame adaptation rail bolted to the common 2-bolt water bottle attachment point. Alternatively, if you have a downtube battery that doesn't fit within the triangle space, you can mount it on the bottom of the downtube, as close to the mid-drive motor or bottom bracket as possible, and secure it with a Triple Bob and hose clamps. Remember to consider suspension travel and ensure the battery won't be hit by the tire when riding off jumps or uneven surfaces.
If you're handy with tools and have access to free or low-cost batteries, you can further customise your setup. For example, attaching a heavy-duty and waterproof Pelican case to the stanchions of a dual-crown fork using accessory clamps is a viable option. If you can't find clamps that match the exact ID of your stanchions, you can use larger clamps and shim them to fit with curved copper sheets made from copper tubing.
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Chain setup
When setting up the chain on your electric bike, there are a few things to consider. Firstly, not all electric bikes require special chains; you can use a standard bicycle chain on any electric bike. However, if your electric bike has a mid-drive motor, you will need a stronger, special chain as these motors put extra stress on the chain, causing it to wear out more quickly. Electric mountain bikes may also require special chains due to the additional stress from jumps, mud, and steep terrain.
If you choose to use a standard bicycle chain, you can simply follow the standard process of putting on a bicycle chain. If your bike has a rear derailleur, loosen the chain and thread it around the front sprocket. Push the arm of the rear derailleur forward to create slack in the chain, then use this slack to thread the other end of the chain around the smallest front sprocket. Release the arm of the rear derailleur and ensure the chain is tight before riding. For bikes without a derailleur, you can usually catch the chain on the sprocket by pedalling.
If your chain has come loose or broken, you can repair it by hooking the chain onto the rear sprocket and hooking as much of the chain as possible onto the bottom of the front sprocket. Then, carefully turn the pedal backward until the chain "catches" and begins to turn around the front sprocket. Once the "caught" portion reaches the top of the sprocket, the chain should run through the bike's gears as normal. Gently pedal forward until the bike shifts into the correct gear.
To replace a worn or broken chain, first remove the old chain. The method for doing so will depend on the type of chain and whether it uses a quick link/master link. If it does not have a quick link/master link, use a chain tool to grab the chain at any link and attach it to the prongs on the tool. Turn the tool until the pin is pushed out, then undo the tool and remove the chain. If it does have a quick link/master link, use master link pliers to remove the chain.
Once the old chain is removed, size the new chain to your bike. For 6, 7, and 8-speed bike chains, drape the new chain over the chainring and large cassette ring at the back without routing it through the derailleur. Bring one end of the chain up to meet the other at the taut spot, then count three whole links down. This is where you will break the chain. Use a chain tool to push the pin out at this section, then mount the chain.
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Maintenance and safety
Maintenance
- Regularly clean your electric bike to prevent dirt, mud, dust, and grime from increasing wear on components.
- Keep the drivetrain well-lubricated to ensure smooth power transmission and protect against wear.
- Regularly check for loose bolts, spokes, and broken parts. Tighten any loose bolts to the manufacturer's recommended torque settings.
- Maintain proper tyre inflation as per the manufacturer's specifications. Check your tyres for cuts, cracks, or bulges that could indicate potential failure.
- Regularly inspect your brakes and brake pads for wear and make basic adjustments as needed.
- Regularly clean and lubricate the chain to ensure optimal performance.
- Keep the battery partially charged and store it in a cool, dry place. Develop good habits for charging and storing your battery to maximise its lifespan.
- Regularly safety-check your bike to ensure all components are securely attached, including brake levers, knobs, and electrical parts.
- If you are not confident in performing maintenance or repairs yourself, visit a dealership or a local bike shop for assistance.
Safety
- Always wear a helmet when riding your electric bike, and consider eye protection and gloves when performing maintenance tasks.
- Use proper lifting techniques when handling your electric bike to avoid back strain or injury.
- Always turn off your electric bike and remove the battery before performing any electrical maintenance.
- Never ride your electric bike if you have doubts about its integrity or safety.
Additionally, be mindful of the weight distribution and balance of your electric bike, especially when installing batteries and other components. As mentioned earlier, reinforcing the fork or installing a torque arm may be necessary to handle the additional forces exerted by the motor. Regular maintenance and safety checks will help you identify any potential issues and keep your electric bike in optimal condition.
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Frequently asked questions
The cost of building an electric bike can vary from under $100 to $500 or more depending on the materials used.
One way to save money is to repurpose an old bike. Another way is to get most of your materials for free. For example, you can ask a medical supply store for old motors and batteries.
Motors have watt ratings, and batteries have voltage and amp-hours. Some countries cap ebike motors: 250 watts in much of Europe, and 750 watts in much of the US.
There are three main types of setups: rear hub, mid-drive, and front-wheel. With a rear hub setup, you swap the rear wheel and add a new freewheel or cassette cogs. With a mid-drive setup, you install a motor beneath your pedals. With a front-wheel setup, you replace the front wheel with one that has a motor.
Building an electric bike can be challenging and requires problem-solving skills. It may also require knowledge of machining tools and craftsmanship, especially when working with the bike chain.
