Molly Ayala
Electric bicycles are a great way to commute, especially in bicycle-friendly cities. They are also a good alternative for those who are unable to cycle long distances. While electric bicycles can be expensive, it is possible to build one yourself for under $100. This can be done by getting most of your materials for free, such as by asking for old batteries and motors at a medical supply store. You can also purchase an electric bike conversion kit, which provides an electric boost to a traditional bike without the cost of a full e-bike. These kits are available for the front or rear wheel and can be purchased with or without a battery.
Characteristics and Values Table for Making an Electric Bicycle
| Characteristics | Values |
|---|---|
| Cost | The cost of converting a traditional bicycle to an electric bicycle is a fraction of the cost of purchasing a new electric bicycle. The yearly operating cost is around $80, plus electricity, repairs, and maintenance. |
| Benefits | Electric bicycles can increase the distance possible with commuter bikes and replace cars for running errands around town. They are also more sustainable and economical than traditional bicycles. |
| Installation Time | The installation time for an electric bike conversion kit can vary, but it typically takes around 30 minutes working at a steady pace. |
| Installation Process | The installation process involves adding a hub motor to either the front or rear wheel or incorporating a drive unit near the bicycle's crank. The Skarper DiscDrive unit is an example of a system that minimises compatibility issues with its click-on system. |
| Battery Life | Most batteries will last for about two years before needing to be replaced, with a price of around $160 for four batteries. The range depends on the terrain, weight of the bike, and level of assistance. |
| Legal Considerations | It is important to check state and local laws before using an electric bicycle on the road to ensure compliance and safety. |
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What You'll Learn
Electric bike conversion kits
There are thousands of electric bike conversion kits on the market, so it is important to do your research to find a reputable brand that suits your needs. Some kits are designed for specific bicycles, so it is important to ensure the kit is compatible with your bike.
Conversion kits typically include a hub motor, controller, display, throttle, and all necessary parts for installation. Some kits, like the Swytch Kit, also include a battery, charger, and pedal sensor. The Swytch Kit is known for being easy to install and environmentally friendly. The E-BikeKit is another popular option, including a hand-built wheel and LCD dashboard, as well as small parts.
When choosing a kit, it is important to consider the voltage and wattage that is suitable for your needs. For example, the eBikeling conversion kit offers options ranging from 36V to 48V and 500W to 3000W. The TongSheng mid-drive kit is another option that offers compatibility with a wide range of bike designs and high torque for steep hills and off-road terrain. However, it does not come with a battery, so you will need to source your own.
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Choosing a battery
Firstly, you'll need to decide on the voltage of your battery. The standard options are 36V or 48V. The higher the voltage, the more power you will have. For example, the TongSheng mid-drive kit requires a 36V battery, and the higher the amp hours (Ah), the longer the range. A 10Ah battery will give you a range of 18 miles, whereas an 18Ah battery will give you a range of 33 miles.
Next, you'll want to consider the type of battery. The most common type of battery for electric bicycles is the lithium-ion battery. These batteries are lightweight, compact, and have a high energy density, which means they can store a lot of energy in a small space. They also have a long lifespan and can be charged many times without losing too much capacity. You can find a wide range of batteries on Amazon, and a recommended brand is Green Cell.
When choosing a battery, you'll also want to consider the connector type. Different motors will require different connectors, so you'll need to make sure the battery you choose is compatible with your motor. For example, the Bafang motor uses a different connector than the Luna Cycle batteries, so you'll need to solder the connections or use a crimp to join them.
Finally, you'll want to think about the placement of the battery. The battery can be installed in a fabric carrying bag above the rear wheel of your bike. This is usually attached to a cargo bracket that fits most standard bicycles at the clamp that fixes the seat height.
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Installing a motor
Firstly, you will need to prepare the bike by sorting out fit and spacing. You will then need to mount the motor with bolts and retaining pieces, ensuring everything is facing the right direction. You should use Loctite on the threads if possible, and allow it to cure for 24 hours.
Once the motor is mounted, you can place the chain on the chainring. "Narrow-wide" chainrings are recommended for single-ring setups as they hold on better. After placing the chain, you should check the shifting and adjust as needed. You should also take note of your bike's chainline after installing the motor.
You will also need to connect the battery to the motor. The connector type will depend on the brand of motor and battery. You may need to solder the connections or use a crimp. When routing the wiring through the bike frame, it is recommended to start with velcro zip-ties.
Finally, you should consider reinforcing the fork, as the bulk of the weight will come from the batteries, which will be installed above the rear wheel. You may also need to reinforce the area where the motor attaches to the wheel, as this can be subject to a lot of force.
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Chain setup
When setting up the chain for your electric bicycle, there are a few important steps to follow. Firstly, ensure that the motor is securely mounted with bolts and retaining pieces, following the manufacturer's instructions and allowing any adhesive to cure for the recommended time.
Next, you can place the chain on the chainring. It is recommended to use a "narrow-wide" chainring for single-ring setups, as the teeth match the chain spacing and provide a better hold. Once the chain is placed, you should test the shifting and make any necessary adjustments. There are excellent tutorials available online, such as the Park Tools tutorial, to guide you through this process.
After mounting the electric motor, take note of your bike's chainline. It is important to consider the gear you are using, as running at low gear can stress the chain, while high gear can burn out the motor if used on multiple hills daily. Therefore, remember to downshift when stopping and shift to higher gears when regaining speed.
Additionally, when routing the wiring through the bike frame, it is recommended to start with velcro zip-ties, which offer more flexibility than regular zip-ties or glue. Finally, ensure that all nuts and bolts are tightened securely, and consider reinforcing the fork area, as this can bear the brunt of the added weight and force from the electric components.
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$259.99
Customisation
Customising an electric bicycle can be a fun and rewarding project, allowing you to create a unique and personalised ride. Here are some key aspects to consider when customising your electric bike:
Motor Placement
One of the primary decisions you'll make is the placement of the electric motor. You can choose to add a hub motor to either the front or rear wheel, each with its own set of advantages. A front-wheel motor can be easier to install and maintain, while a rear-wheel motor may provide better traction and handling, especially when climbing hills.
Battery Selection
The battery is a crucial component of your electric bicycle, and selecting the right one is essential. Consider the voltage and capacity of the battery, ensuring it matches your motor's requirements. For example, a 36V battery is common, but you may need a higher voltage for more power. Additionally, look at the range the battery can provide. A higher capacity, such as an 18Ah battery, will give you a longer range of around 53km.
Compatibility
Ensuring that all the components of your electric bicycle are compatible is vital. This includes making sure the battery connector matches your motor, and if not, you may need to solder or crimp the connections. Additionally, consider the compatibility of the motor and battery with your bicycle's design and wheel size. Most conversion kits are designed for standard adult bike wheel sizes, typically 26" in the US.
Performance and Usage
Think about how you plan to use your electric bicycle. If you intend to ride on steep hills or off-road terrain, consider a system with high torque for better performance in these conditions. Additionally, consider the gear you'll be using. Running at low gear can stress the chain and cassette, while high gear can burn out the motor if used excessively on hills. Adjusting gears appropriately when stopping and regaining speed can help mitigate these issues.
Aesthetics and Comfort
Customising the aesthetics of your electric bicycle can make it truly yours. Consider the colour, frame style, and any additional features you may want, such as a cargo bracket for carrying items. Additionally, think about comfort features like ergonomic handlebars, a comfortable seat, and adjustable suspension for a smoother ride.
Customising an electric bicycle involves a range of considerations, from performance and compatibility to aesthetics and comfort. By carefully selecting and customising the various components, you can create a unique and personalised electric bicycle that suits your specific needs and style.
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Frequently asked questions
It is possible to build an electric bicycle for under $100. You can achieve this by getting most of your materials for free. For example, you can source a motor and batteries from a medical supply store. You can also buy a second-hand bicycle to convert.
Electric bicycle conversion kits provide an electric boost to a traditional bicycle without the cost of a full e-bike. This can be done by adding a hub motor to the front or rear wheel or by adding a drive unit near the bicycle's crank. There are thousands of conversion kits on the market, but it is important to make sure that the one you choose is legal and compliant with the laws in your territory.
Make sure that you tighten the nuts securely. You may also want to install a torque arm or otherwise reinforce the fork, as it may not be designed to take force in that area. The bulk of the weight will come from the batteries, which will be installed on a cargo bracket above the rear wheel, along with the motor driver.
