Beatrice Lang
Electric bicycles are a convenient mode of transport, especially for commuting in cities and urban areas. While high-quality electric bicycles can be expensive, it is possible to build your own electric assist bicycle using a conversion kit and a battery. The process is straightforward and can be done inexpensively. The key components required are a bicycle in good working order, a conversion kit, and a battery. The conversion kit typically includes a throttle, speed controller, and a wheel with a hub motor. It is important to ensure that the wheel in the kit matches the size of the existing wheels on your bicycle. Additionally, it is recommended to choose a battery with a suitable voltage and capacity, such as a 36- or 48-volt battery, to allow for both speed and comfort.
| Characteristics | Values |
|---|---|
| Electric bicycle conversion kits | Mid-drive, hub motor, front-wheel, rear-wheel |
| Motor power | 250 watts (EU/UK), higher in the US |
| Speed | Up to 25 km/h (EU/UK), varies in the US |
| Battery voltage | 36V, 48V, 60V, 72V |
| Battery capacity | 10Ah, 20Ah |
| Battery life | Around 2 years |
| Installation | Easy, bolt-on, one bolt, Allen wrenches |
| Compatibility | Check bottom bracket, fork, rear, wheel size |
| Brakes | Disc brakes, front-disc brakes |
| Gears | Single gear, multiple gears |
| Cost | $500 (budget), $3000-$5000 (high-end) |
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What You'll Learn
Choose a conversion kit
There are several electric bike conversion kits available on the market. The best kit for you will depend on your location, your personal requirements, and the type of bike you own.
Before purchasing a conversion kit, it is important to familiarize yourself with the laws regarding e-bikes in your region. For example, in the UK and EU, anything with a speed limiter of over 25km/h is classified as a moped, whereas in the US, a more powerful electric bike motor can be used.
When choosing a conversion kit, consider your range and journey needs. For example, if you live in a hilly city, you may want a kit with more top-end power. You should also check that the system is compatible with your bike.
Some popular conversion kits include the Swytch Kit, the Bafang front hub-based motor, the TongSheng mid-drive motor, and the Voliamart rear wheel kit. The Swytch Kit includes everything you need to convert your bike to electric, such as the wheel, power pack, pedal sensor, charger, and cables. It also offers a range of power pack capacities and wheel options to choose from. The Bafang and TongSheng motors are compatible with a wide range of bike designs and offer high torque for steep hills and off-road terrain. The Voliamart rear wheel kit delivers plenty of power and offers five power options, but it requires mechanical competence for installation and does not include a battery.
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Select a battery
When selecting a battery for your electric-assist bicycle, it is important to consider the various factors that will impact your experience. Here are some key considerations to keep in mind:
Voltage
The voltage of your battery will determine the power and speed of your electric bicycle. Common voltage options include 36V and 48V, which are suitable for speeds up to approximately 28 mph (45 km/h). If you desire higher speeds, you can opt for 60V or 72V batteries, but these are typically mounted in frame bags due to their larger size and are recommended for those with light motorcycle-riding experience. The higher the voltage, the more powerful your bike will be, but also consider that higher voltages will result in larger and more expensive batteries.
Battery Capacity
The capacity of the battery, measured in ampere-hours (Ah), defines how long it will last. For short trips, a 10Ah battery is sufficient, while a 20Ah battery is more suitable for longer journeys. Consider your typical usage and choose a capacity that aligns with the distance you plan to cover on a single charge.
Compatibility
Ensure that the voltage and capacity of your chosen battery are compatible with your electric bicycle conversion kit. In some cases, purchasing the battery and conversion kit from the same manufacturer can simplify the installation process and ensure compatibility. Additionally, check the mounting options for your battery. Most people prefer frame-mounted batteries for their simplicity and improved handling due to a lower center of gravity.
Battery Life and Replacement
Keep in mind that electric bicycle batteries typically last for about two years before requiring replacement. Factor in the cost of replacement batteries into your long-term ownership plans. Additionally, consider the availability and price of replacement batteries for your chosen voltage and capacity to ensure a sustainable supply.
Legal Considerations
Before selecting a battery, understand the local laws and regulations that govern electric bicycles in your region. Different places have varying rules regarding power, speed limitations, and throttle control. For example, in the UK and EU, a motor must have a continuously rated power output of no more than 250 watts, while the US allows more powerful motors. Ensure your battery selection complies with the legal requirements to avoid any issues.
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Install the kit
To install the kit, you will need a bike in good working order, a conversion kit, and a battery. The most natural-feeling electric bike conversion kits are those with a mid-mounted motor. If you also want to be able to pedal, pair the mid-mounted motor with a torque sensor. This will add a percentage of power to your pedalling, amplifying the effort you put in.
The easiest kits to install are those with one-bolt installation, like the Gboost. You should also consider whether you want to replace the front or back wheel. It is much easier to replace the front wheel, so opt for a kit where the hub motor is on the front wheel. Ensure the kit comes with a wheel that is the same size as the existing wheels on your bike.
If you are installing a cadence-based system, you will need to attach a cadence sensor so that the bike knows when you are pedalling and need assistance. If you are installing a torque-based system, you will not need to attach a cadence sensor as the system will detect how hard you are pedalling.
Next, attach the speed controller to the frame of your bike above the chain, and attach the throttle to the handlebars. Then, connect the battery to the speed controller and throttle and mount the battery on your bike. Choose a 36- or 48-volt battery with a capacity of 10Ah or 20Ah. The higher the voltage of your bike's battery, the more powerful your bike will be. The capacity of the battery defines how long it will last.
Finally, if you are using a battery with a voltage above 60V, you will likely be limited to a frame bag-mounted battery, as higher-voltage batteries rarely come in cases designed for easy mounting.
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Understand local laws
Electric bicycle laws vary across different regions and states. Therefore, it is important to understand the local laws that govern electric bicycles in your area before building or purchasing one. Here are some key considerations:
Licensing and Registration:
Some regions may require a license or registration for electric-assisted bicycles, while others may not. For example, in Canada, Power Assisted Bicycles (PABs) do not require a license to operate, whereas in some US states, electric bicycles may be treated as mopeds, requiring a standard driver's license.
Speed and Power Limitations:
Local laws often impose speed and power restrictions on electric bicycles. For instance, in the US, there are different classes of e-bikes based on power, speed limitations, and the presence of a throttle. Similarly, in Canada, PABs are defined as bicycles with a motor of 500W or less and a maximum speed of 32 km/h.
Allowed Areas of Operation:
Local laws may restrict the areas where electric bicycles can be operated. Electric bicycles may be prohibited from sidewalks and natural surface trails, and certain bikeways or bike paths. For example, in the US, local government ordinances can permit or ban specific classes of electric bicycles on dedicated bicycle paths and trails.
Labelling Requirements:
Manufacturers and distributors of electric bicycles are often required to apply labels specifying the classification, top assisted speed, and motor wattage. These labels must be permanently affixed and prominently displayed. If modifications are made to the bicycle that change its speed or motor capabilities, the label must be replaced to reflect the new specifications.
Insurance and Liability:
Depending on your local laws, there may be insurance and liability considerations when operating an electric bicycle. In some regions, electric bicycles may be subject to the same insurance and liability requirements as motor vehicles.
It is important to consult official government sources and local authorities to understand the specific laws and regulations applicable to electric-assisted bicycles in your area. These laws are subject to change over time, so staying informed is essential.
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$259.5
$37.04 $50
Consider the cost
Building an electric-assist bicycle can be a cost-effective way to upgrade your current bike and make cycling more accessible. However, there are several costs to consider when building your own electric-assist bicycle.
Firstly, you will need to purchase a conversion kit, which typically includes a throttle, speed controller, and a wheel with a hub motor. Some kits may also come with gauges, displays, and brake levers, but these are optional. The cost of conversion kits can vary, and it's important to ensure that the kit is compatible with your bike, especially the wheel size.
Secondly, you will need to buy a battery separately, which can add a significant cost. The battery voltage and capacity will impact the power and speed of your electric-assist bicycle. A higher voltage battery, such as 36 or 48 volts, will provide more power, while the capacity, measured in Ah, will determine how long the battery lasts before needing to be recharged.
Thirdly, you may need to purchase additional tools and equipment for the installation process, such as Allen wrenches. These tools may increase the overall cost of the project.
Finally, it's important to consider the ongoing costs associated with an electric-assist bicycle. The battery will need to be replaced eventually, and there may be maintenance or repair costs over the lifetime of the bicycle.
While building your own electric-assist bicycle can be a cost-effective option compared to buying a new electric bicycle, it's important to weigh the costs of the conversion kit, battery, tools, and ongoing maintenance to make an informed decision.
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Frequently asked questions
You will need a bicycle in good working order, a conversion kit, and a battery. Conversion kits will include a throttle, speed controller, and a wheel with a hub motor. You will need to purchase a battery separately, ensuring that the voltage and capacity are compatible with the conversion kit.
The most natural-feeling electric bike conversion kits have a mid-mounted motor. If you want to do some pedalling, pair the mid-mounted motor with a torque sensor. The TongSheng system has a maximum torque of 80Nm, adding between 36 and 300 per cent to your pedalling power. If this is your first time building an electric bike, opt for a hub motor-based kit as they are easier to install.
The higher the voltage of your bicycle battery, the more powerful your bike will be. Choose a 36- or 48-volt battery for speed and comfort. The capacity of the battery defines how long it will last. A 10Ah battery is suitable for short trips, while a 20Ah battery is better for longer journeys.
