Building An Electric Bike On A Budget

Building an electric bike for less than $100 is possible, but challenging. It requires a substantial knowledge of machining tools, and the ability to source most of your materials for free. You'll also need to be a good problem solver, as the materials you find will likely be different from those used by others. There are a few tricks and tips to help you source your materials, and you'll need a range of tools, including a lathe, welder, basic hand tools, a dial caliper, a drill press, a chain breaker, a freewheel remover, a grinder, and metal cutting tools. You can also buy conversion kits, but these are considerably more expensive than $100.

Finding free materials

Building an electric bike for less than $100 is possible, but it will be challenging. The key to achieving this is to source most of your materials for free. Here are some tips for finding free materials to build your electric bike:

• Look for old bikes that people no longer want. Check your garage, attic, or basement for any old bikes that you can convert. You can also ask your friends and family if they have any unwanted bikes, or keep an eye out for free bikes being given away online or on community noticeboards.
• Search for free or low-cost materials online. Websites like Craigslist, Freecycle, or Facebook Marketplace often have people giving away items for free or at a low cost. You can also check online forums or groups dedicated to electric bike building, as members may have spare parts or materials they are willing to donate or sell cheaply.
• Reuse and recycle materials. Look for items that can be repurposed for your electric bike build. For example, you may be able to find old bike parts, motors, batteries, or other electronic components that can be salvaged and used in your project.
• Contact local bike shops or repair centres. They may have old bike frames, parts, or accessories that they no longer need and would be willing to give away. They may also have advice on where to source free or low-cost materials.
• Check with local schools or universities. Sometimes, educational institutions may have old equipment or parts that they no longer need and would be willing to donate to a good cause.

Remember, when sourcing free materials, it is essential to use your problem-solving skills and be creative. The materials you find may not always be exactly what you need, so you may need to adapt and modify them to fit your project.

Using conversion kits

Although it is not possible to build an electric bike for under $100, even with the cheapest conversion kits, you can still use a conversion kit to give an old bike a new lease of life. A front hub motor kit is the cheapest way of electrifying an old bike. This kit places the motor in the front wheel hub and is easy to install. It's just a case of replacing the wheel and finding somewhere to fit the controller and the battery. You can also fit a rear hub motor kit. This setup provides better traction and stability but is more involved in installation. Some technically-minded people opt for mid-drive motor kits. This puts the motor near the bike's bottom bracket and is directly connected to the drivetrain. Mid-drive kits give you better weight distribution and performance but are more challenging and costly to fit.

Tools and materials needed

Building an electric bike for less than $100 is possible, but it will be challenging. You will need to be resourceful and find ways to get most of your materials for free. You will also need to have good problem-solving skills and substantial knowledge of machining tools.

The tools and materials you will need include a lathe, a welder, basic hand tools (such as a hacksaw and pliers), a dial caliper, a drill press with many bits, a chain breaker, a freewheel remover, a grinder, metal cutting tools, and basic bike tools. You may also need optional tools such as a v-block, surface grinder, mill, and tap and die.

The materials you will need include angle iron, a 9-tooth, ANSI number 40 machinable hub sprocket, two bearings, steel round stock, and a 4-inch diameter v-belt. You will also need to source an old bike to convert.

To electrify the bike, you can buy a front hub motor kit, which places the motor in the front wheel hub and is easy to install. This is the cheapest way to electrify an old bike. You can also fit a rear hub motor kit, which provides better traction and stability but is more involved in installation. Alternatively, some technically-minded people opt for mid-drive motor kits, which put the motor near the bike's bottom bracket and connect directly to the drivetrain.

When setting up the chain, you will need to break the chain in the correct link to ensure that the links you break will mesh.

Setting up the chain

To set up the chain, you will need a chain breaker. You should have already broken the chain to take it off the bike. Now, you will set the chain up like normal, going correctly through the rear derailleur and meshing onto the middle sprocket on your rear cassette. Make sure that the rear derailleur is in the right position to ride, and not all bunched up or on the wrong gear. Next, lay your two chain ends side by side so that you can get close to the correct length of the chain. This is the hardest part. You will then break the chain in that link, making sure that the links you break will mesh.

If you are installing a front hub motor kit, you will need to replace the wheel and find somewhere to fit the controller and the battery. This is the cheapest way of electrifying an old bike. You can also fit a rear hub motor kit, which provides better traction and stability but is more involved in installation. Some technically-minded people opt for mid-drive motor kits, which put the motor near the bike's bottom bracket and are directly connected to the drivetrain.

Machining skills

Building an electric bike for less than $100 is possible, but it requires substantial knowledge of machining tools and problem-solving skills.

The first step is to source most of the materials for free. This can be challenging, and you will need to be resourceful and creative in your search.

The next step is to gather the necessary tools and materials. A lathe is mandatory, as well as a welder, basic hand tools (hacksaw, pliers, etc.), a dial caliper, a drill press with various bits, a chain breaker, a freewheel remover, a grinder, and metal cutting tools. Basic bike tools are also recommended, and you may need optional tools like a surface grinder or mill.

The process of converting a normal bike to an electric one involves breaking and setting up the chain, ensuring the rear derailleur is in the correct position, and breaking the chain to the correct length. This requires precision and attention to detail to ensure the chain meshes correctly.

Some people opt for motor kits, which can be front hub, rear hub, or mid-drive. These kits vary in price but can be more affordable than building the bike from scratch. The front hub kit is the cheapest and easiest to install, while the rear hub kit provides better traction and stability but is more complex to install. Mid-drive motor kits place the motor near the bottom bracket and connect directly to the drivetrain.

Frequently asked questions