In our world, full of a variety of machines and automated mechanisms, bicycles persist in their popularity. They are being altered, modernized, new models of incredible shapes and sizes are created. But they are based on the same two wheels. And today we propose to turn an ordinary bicycle into an electric bike.
Such models are widely discussed on the web. The controversy around them does not subside, because alterations sometimes cost more than cars. But the author of the video did not seek glamor or stunning designs. Rather, on the contrary, his electric bike model can be called budgetary. All parts can be purchased on Chinese sites or in domestic online stores. The bike itself is not overloaded, but thanks to the alteration it looks quite modern. You can make it in a regular home workshop. Is it worth it and whether it is necessary to bother coming up with a "bicycle" again, let's find out together.

Materials:

• Regular bike;
• ... You can, of course, take a DC motor and control it with the help;
• Lead acid battery GP1272 F2 - 2 pcs;
• Metal plate (preferably stainless steel or aluminum);
• Aerosol car paint;
• Bolts, screws, nuts, washers;
• Wiring with terminals for connecting contact groups;
• Insulating tape;
• Tight anodized tension spring;
• Powerful hinge with small shelves;
• Metal plates for clamps and gaskets;
• Section of a shaped pipe 15x15 mm, length - about 50 cm;
• Double tape.

Tools:

• Drill or screwdriver;
• Bulgarian (angle grinder);
• Welding inverter;
• Drills, cutting and grinding discs for grinders;
• Open-end and hex key set;
• Stripper for crimping terminals on wires;
• Screwdriver, pliers, paint knife and tape measure with pencil.

We collect the electric bike

The author took a ready-made kit for converting a skateboard into an electric board as the basis for the driving mechanism of his electric bike. It can be bought at Chinese sites, complete with an engine and belt drive for around $ 100. A 24 volt motor is provided for them, which runs without brushes. For such devices, this is the most advantageous design, the weight is about 500 g, and the power is 1800 W! Of course, with such characteristics, it has enough traction to easily pull the bike with the rider.

Step one - make an electric drive on a suspension

First of all, we put a mounting platform for the engine and a belt drive on the suspension axle. Next, we attach the wheel from the skateboard with the gear to the suspension axle.

Now you need to correctly align the mounting platform for the engine. We turn it perpendicular to the vertical axis of the suspension, and tighten the clamping bolt with a hex wrench.

We install the engine on the seat, tighten it with four screws and put on a small gear for the belt drive.

Step two - connect the electrical circuit

The suspension assembly is ready, now it can be connected via the speed controller to the batteries. We connect them in series. The author of the video added a rheostat switch to the circuit in order to be able to smoothly change the voltage and trace the operation of the engine at the same time.

We disconnect the rheostat (we will no longer need it), and connect the radio-controlled controller-handle with the transmitter-receiver. This equipment is used by skateboarders to control electric boards. A convenient trigger on the handle will allow you to operate such a device easily and naturally.

Step three - fix the propulsion module to the bike frame

Installation of such a module has its own characteristics. If it is firmly fixed to the frame of the bike, the wheel from the skateboard can rub off the bicycle tire, and the engine can overheat from excessive stress and burn out. In the free position, such a suspension will dangle like unnecessary ballast while driving, especially on country roads. Functional mounts require a fulcrum and linkage to push the skateboard wheel against the tire. We will do it now.
Raise the rear wing of the bike higher to place the propulsion module in its place.

The suspension needs to be slightly trimmed by removing the unclaimed second axle from it. We clamp the device in a vice, and with a grinder (angle grinder) cut it off flush with the mounting platform for the board. We clean the cut edges with a sanding disc.

Cut out the protective cover for the driving module from the sheet of metal. We mark it according to the size of the device, and cut it off with a grinder. To secure the engine, we make holes for the mounting plate, and we sit it on the bolts.

The movable module will be attached to the frame with a small but powerful hinge. She will be the axis of our device. On the back of the protective cover, we fix the loop with a welding inverter. We clean the seams with a grinder.

Using a piece of a regular door hinge, we make a clamping clamp for fastening to the frame. We paint the protective cover with a loop with an aerosol in the color of the bike frame. We fasten it to the bolts to the device of the movable module.

We mount the entire device with a powerful bolt. We drill a hole in the hinge and frame, press the bolt connection through it with open-end and spanner keys. You need to adjust its position so that the skateboard wheel is parallel to the wheel slope, and would move in the same plane with it.

Step four - preparing the lever

The clamping mechanism is made in the form of a small lever. It rests on a stiff spring determined for compression.
We fix a bolt on the cover, which will restrain the movement of the spring and prevent it from jumping off.

We make a lever from a 15x15 mm profile pipe. We mark a corner cut at one end of it, and a 90-degree bend at the other. We make cuts with a grinder, and weld the joint with a welder.

We make a crimp clamp from an aluminum plate to secure the lever to the frame. After cleaning the seams, you can start painting.

Step five - install the electrician on the bike

Place the battery banks on the diagonal cross member of the frame. We rest them in a vertical rack and wrap them tightly with tape, leaving only the contact terminals open. We install the lever on the frame, fix the clamp to the bolted connection, and tighten it with a screwdriver. We put the spring on the seat, and check the pressure to the tire.

This article will discuss how you can turn an ordinary bicycle into an electric one with your own hands. Such a bicycle will run on a battery, which, when discharged, can always be recharged and then continued. Of course, there are already many ready-made solutions for this kind of homemade products, for example, a motor-wheel, but here everything is assembled from scratch.

According to the author, the homemade product fully justified its hopes. Since the engine is not very powerful here, the bike cannot move from its place, first you need to accelerate it with your feet to a speed of 10-15 km / h, which is not so difficult. Well, then the electric motor is turned on, which supports the movement of the bicycle and you no longer need to pedal. An electric motor accelerates the bike to 34 km / h when driving in a straight line.

The bike consumes 100-300 watts when driving on a straight road. When driving downhill, consumption increases to 600-800 watts, in order to save money, you can help with your feet.

The peak current consumption of the motor was 1200 watts.

Materials and tools for assembling homemade products:
- electric motor type 6354 kv200

- speed controller ESC

- wattmeter (copy of Turnigy 130A);

- battery type LiPO 6S 22.2V 5a-h;

- the gas handle from the bike (controlled by the thumb);

- brake levers (they have a pressure sensor);

- rear rack (used as a structural element);

- 16-tooth ratchet;

- cogwheels and belt (ready-made).

Bicycle upgrade process:

Step one. Installing an asterisk
In most cases, the sprocket is attached to the spokes, but the author decided to abandon this design. As a result, the sprocket was bolted to the brake disc. Also on the disc you can see six screws in a circle and two closer to the center of the brake disc. These screws fix the threads so that the disc does not loosen when driving.

Step two. Install the ratchet
The ratchet is installed on the cup from the carriage; a ring from the native cup is used to fix it.

Step three. Rear hub
The rear hub acts as an intermediate shaft. It is installed in a U-shaped section of a professional pipe.

Step four. Installing a large gear wheel
A pin is used to fix the gear wheel. Otherwise, the bushing will clamp itself with the cones. The gear has a groove and the pin is inserted into a hole that is in the shaft. As a result, the pin fits into the groove of the wheel.

Step five. Small gear
Two gougeons are used to fix the small cogwheel.

Step six. Installing the engine
To mount the engine, a standard crosspiece is used to the L-shaped structure, which was found by the author in the bins.

Step seven. Fastening the chain tensioner
The chain tensioner is attached to the luggage compartment side element. Everything is mounted on a structured plate made from a thick sheet of aluminum.

General view of the bike

Step eight. Homemade electrical circuit
How the circuit works can be seen in the picture. It has been slightly improved in comparison with the original. So, for example, the variable resistor was removed in the servo tester, and a hall sensor from the throttle control knob was installed in its place. The author installed a 1 kOhm back-up resistor in the button circuit, without it spontaneously switching modes, probably due to interference.

Another nuance of the electrical part is that the author has separated the power plus and the measuring plus. Also, in the future, it makes sense to put an isolated 5V to 9V converter, due to the fact that there are understated power readings.

As for the battery, it works without BMS. To prevent overdischarge, I used a battery monitor that was set to 3.3V. When the voltage gets too low, the device starts to make a sound.
The battery is charged by the IMAX B6 clone, the Li-Io mode with balancing is used.

Many people like bicycles for their comfort and ability to exercise. They are used as a means of transportation in urban areas with complex traffic. But not everyone wants to waste energy to reach the desired location.

Often the speed of a conventional device is not enough. Then ideas are born on how to create an electric bike from improvised means, so that it meets the requirements of environmental friendliness and is more functional. The fact is that not everyone can afford to purchase a factory version.

What are its advantages?

First of all, it is considered a mobile device for movement, since it can pass in the narrowest parts of the road. And he is not afraid of traffic jams of varying complexity.

Consider all the advantages:

• Will be an excellent alternative for using public transport;
• An e-bike can be operated without the need to obtain a license;
• He does not need gasoline, however, he will often have to charge the voltage controller;
• Helps maintain physical fitness.

To determine that you need this type of transport, pay attention to the photos of homemade electric bicycles of various configurations.

They can differ in design features and functional characteristics: weight, available speed, range on one charge.

How to create it yourself?

First of all, let's figure out what is needed to assemble an electric bike on our own. It is very important to find a bike that is capable of withstanding a serious load. A light class model will not work - it must be a sturdy specimen.

But the most important thing is to get an engine with sufficient power. In addition, you will need the following list of additional elements:

• Controller based programming capability;
• Two mechanical disc brakes;
• Acid type batteries;
• A set of fuses and switches;
• "Asterisk" based on 66 and 123 teeth;
• Stainless steel fasteners for secure engine mounting.

But this is not enough, since without the necessary tools it is difficult to fix all the parts.

How to collect?

Do-it-yourself step-by-step assembly of the electric bike. Modifications to the brakes and front fork need to be done, then move on to the rear. After that, it connects to the bike: the motor, the battery and the resistor - this happens alternately.

The scheme of the simplest finished model should include:

• Reliable body from the usual version of the bike;
• An efficient engine;
• Power supply;
• Battery;
• Correct version of the variable resistor;
• Chain similar to the moped version.

You can create many different circuits based on the same battery. However, speed and functionality may vary. To correctly create a reliable option, you must have knowledge of physics. We are talking about Ohm's law, the possibilities of electrical conductivity of materials and resistance.

But the regular version is simple and easy to create yourself. During the assembly process, you can notice some shortcomings and fix them or find a way to modify the electric bike.

Engine

Thinking about how to make an electric bike on their own, everyone comes to one thing - you need a reliable engine. In order for it to work efficiently, it is necessary to ensure that the voltage and current strength match.

If the model has a power equal to 400 W, then, taking into account a reliable gearbox, you can reach a speed of about 30 km / h. And if you install a capacious battery, then the mileage can reach 30 kilometers.

Important: Do not forget about the balance between the battery capacity and its voltage, capacity and voltage of the unit. For a 500 W engine, you will have to install a 12 V battery with 40 amperes / hour. In other words, rely on Ohm's Law and then the electric bike circuit will last longer.

Note!

What controller is needed and how to adjust the resistor?

The controller changes the traction level of the e-bike. And this is primarily what distinguishes it from the regular version. This device helps to optimally distribute traction to all wheels and ensure smooth operation of the unit.

For this version, throttle grips are required. With a variable resistor, it is easy to regulate the speed and speed of the engine.

After calculating the required energy level, the opening contacts are mounted on the brake handle (in a closed form). By pressing the contacts, the circuit will open or close, and the motor will accordingly slow down or accelerate.

Conclusion

Now you have a simple instruction on how to assemble an e-bike with your own efforts. It remains to advise not to overstrain the battery by increasing the unit speed.

Protect your bike from direct sunlight as battery capacity will be significantly reduced by overheating. We recommend that you accelerate with your muscles to save precious energy.

Diy photo of electric bicycles

Note!

Note!

The popularity of such a compact, lightweight and safe form of transport like the folding electric bike is growing from year to year. How to make such a design with your own hands in order to save money on the purchase?

Benefits

Experts say that a little ingenuity is enough to make a fashionable and durable design, buy the appropriate parts - and the faithful electric horse is ready. It has many advantages:

• on such transport, you can perfectly move around the city full of traffic jams;
• it does not require a driver's license;
• no need for fuel, only recharging for the electric controller;
• it contributes to the maintenance of athletic form due to the muscular strength used;
• dIY homemade e-bike helps to be independent from shops and market prices.

The average unit reaches speeds of up to 42 kilometers per hour, and at cruising speed goes under 26 kilometers per hour.

The entire device will weigh up to 35 kilograms. To make a high-quality and reliable model from available materials, it is worth using the recommendations of experienced craftsmen.

We make wheeled transport ourselves

How does the assembly of the entire model begin? First, it is worth deciding how the result should look like and what goals we want to achieve with the help of this transport. You can buy a special kit for an electric bike - it greatly simplifies all the assembly work. But the most important thing that is needed is the unit itself with a thickened frame, on which an electric motor can be installed.

You can find the necessary parts and components at sales, in inventor stores, in markets with technical goods. Do-it-yourself electric bike in 30 minutes is quite within the power of an advanced student.

Main components

Usually you need a 48 volt motor, a sturdy bike that can handle it, few tools and bindings. And also patience and resourcefulness, readiness for technical tests.

Additionally you will need:

• special controller with programmable control;
• acid batteries for the power supply system;
• disc brake (2 pcs.) rotary type, mechanical;
• moped chain;
• "Sprocket" for 13 and 66 teeth;
• switches;
• circuit breakers;
• stainless steel motor mounts.

Some craftsmen prefer to assemble a folding bike, which in seconds can turn from a regular bike into a cargo bike or fit in the trunk. The collapsible version is convenient for a variety of reasons - reduced wheel size, ease of transportation in an elevator.

The essence of the modification consists in cutting the frame, to which the connecting nodes are welded in two places. They are fixed with special bolts, screws and the procedure for assembling and disassembling the unit at home takes less than 1-2 minutes.

Engine selection

A homemade e-bike requires the installation of an appropriate technical superstructure that will facilitate muscular effort. The main element of the entire structure is the engine. It is selected in accordance with the required voltage and amperage. In this case, the power received should be in the region of 400 watts, then it will be possible to reach speeds of up to 30 kilometers per hour with a gearbox. The travel range can also be up to 30 kilometers, depending on the power of the battery.

Before choosing a model, it is important to consider the balance between battery voltage and capacity and engine voltage and capacity. For example, when choosing a 500-watt, 12-volt motor, you need a 40 amp per hour battery. The allowed capacity is calculated using Ohm's Law. With a normal discharge rate, the battery will last longer and more reliably. To save energy, it is better to accelerate with muscle power while standing on the pedals - this will save energy at the level of 1.2. It is better to spend the charge on more difficult areas while moving: on hills and hills, on a dirt road.

Resistor setting

An adult tricycle or two-wheeled electric bike equally requires throttle grips. The variable resistor variant helps to control the change of speeds and the number of revolutions of the engine. Having calculated the AC power, take the appropriate device with the desired voltage. Contacts are installed on the brake lever for opening - their position is always closed, it passes electricity through the circuit. Pressing the contacts opens and closes the circuit - the motor stops or speeds up the operation.

Typically a standard e-bike kit contains the necessary parts for assembly. The task of the master is to make the engine stop when the brake lever is pressed. To do this, take two aluminum pieces. One is installed on the moving parts of the brakes, the second on the fixed ones. Connecting this combination to a motor break, which is welded onto the brackets, provides a functional electric brake.

Scheme development

To assemble an electric bike with your own hands in 30 minutes, you need a minimum of skills, but knowledge of some laws of physics is mandatory.

For example, Ohm's law, resistance of materials or electrical conductivity of different substances. By drawing up a simple diagram in accordance with the classic technical requirements, you can clearly see the gaps in the design, the reasons for possible malfunctions or the possibilities for further modification.

The electric bike diagram includes the following elements:

• bicycle body;
• current source;
• engine;
• variable resistor for insertion into the open circuit;
• battery.

Different schemes make it possible to improve the invention and accelerate transport to higher speeds with the same battery.

Choosing a controller

The main difference between a classic vehicle and an electrified one is the presence of a special regulating device. This is an e-bike controller, which is a box that manipulates the traction of the entire unit. If your country has a speed limit on cycling, this device will help you set the limit while riding. Most often it is 25 kilometers per hour.

The design of such a sensor does not include electric brushes.

But there is a processor that tracks the position of the rim magnets. The controller allows you to optimally distribute the load on the wheels, reduce heat generation, and the engine - to normalize the efforts to move without jerking.

The developed motion algorithms help to move evenly and at the same speed.

Operating rules

Today you can see with your own eyes a lot of vehicles assembled by craftsmen. They perform mountain climbing, dangerous stunts, conquer gorges. But you can just enjoy a good, reliable car that got a second wind thanks to the engine.

It is important to follow the technology of making an electric bike with your own hands in 30 minutes, but you should be equally attentive to the recommendations for the correct use of this vehicle.

Do not constantly overstress the battery by exceeding the set speed in the engine. Also, the bike should not be placed in the sun - the battery can overheat and lose capacity by 80% of its original volume. Temperatures around 40-45 degrees are especially dangerous in hot countries.

Do-it-yourself electric bike in 30 minutes can be assembled quite efficiently. It will last for many years if you follow the security measures and correctly follow all the recommendations.

So, we figured out how to make a homemade folding e-bike. As you can see, this is not difficult.

There are two ways to convert a bicycle to an electric one. Purchased parts undoubtedly look more spectacular, and the layout will be so dense that visually any changes in the design will be almost imperceptible. And yet, making an electric bike with your own hands provides many advantages, including in terms of its maintainability. The main thing is to understand which of the materials at hand can be used and how to assemble it correctly.

The choice of accessories for the e-bike

Engine

Judging by the reviews on the forums, most home craftsmen are quite satisfied with the engine from a household washing machine of the order of 350 - 400 watts. By the way, many industrial-made electric bicycles, for example, Wellness HUSKY (price within 51,000 rubles), are equipped with just such engines. The main thing is to choose the right type of electric motor. The brushed motor works equally well on both AC and DC mains.

The pursuit of an increase in power is a futile business. The only advantage is that the tractive effort will increase when the e-bike is moving uphill, but the speed is unlikely to increase significantly.

By the way, on the Internet there are homemade products based on a screwdriver. This experience should not be adopted - it is hopeless. Who knows what kind of household power tool is already understood. And the price of batteries "bites" to it, and the service life with this use is season 2, no more.

Battery

Before choosing a battery, you should decide what exactly you need an electric bike for. For long journeys and the battery capacity must be appropriate. How to proceed? Build several into a battery or choose one, but with a large charge? In the first case, the installation becomes more complicated, since all the elements will have to not only be fixed, but also connected into a single power / power scheme. Secondly, a significant increase in the size of the battery. Therefore, finding a place for her will not be easy. But from the point of view of the convenience of completing an electric bike, this option is preferable.

According to those who have already assembled an electric bike with their own hands, optimal battery parameters - 48 V (20 A / h, at least)... An engine (380 W) is selected for it. It is enough to provide a speed of up to 40 km / h on rough terrain. The charge is enough for a couple of hours. According to the type of battery, the best is Ni-MH battery. With regard to an electric bike, its main advantages are large capacity, increased operational life. And the price is quite reasonable.

If basically an e-bike can be assembled from scrap materials, then a battery should be bought. A 5000 mAh product will allow you to travel up to 10 km without recharging at a speed of 20 km / h. When driving around the city (for example, to work and back) it is quite enough.

Transfer type

If the engine is from household appliances, then there is already a pulley on the shaft. Therefore - the transmission is belt. This is the simplest solution, since all that remains is to install the analog on the wheel (of course, the rear one) You can replace the pulley with a ring gear. The 52T sprocket fits perfectly. It will turn out something like this.

Charger

You should also worry about it in advance. If the battery is selected, then it is not difficult to purchase the appropriate model that matches the parameters.

Features of e-bike assembly

Any bicycle model can be taken as a basis, therefore, it makes no sense to paint the order of work in the form of step-by-step instructions. But it is worth paying attention to certain nuances of making an electric bike with your own hands. Everything that will not be said will be clearly demonstrated by illustrations.

• If the frame is metal, then most of the mountings can be made by welding. It is more difficult with an aluminum or carbon version of the body, you will have to drill holes and use nuts and bolts to fix the components of the circuit.
• For an emergency stop, the e-bike engine will have to be turned off. It is more convenient to place the electric / circuit breaker in the brake lever.
• The optimal place for the "ignition switch" is the headlight. If necessary, you can also place a signal button in it, although this is superfluous for an electric bike. Given the low speed, it will be possible to warn the pedestrian with a voice. And it is hardly advisable to complicate the circuit, since the sound signal is one of the consumers of electricity. And the capacity of the battery is not unlimited.

How can you retrofit an electric bike

Those who are versed in electrical and radio engineering are trying to make the model more perfect. But it will not work to collect it only from the materials at hand - you will have to acquire something, which means spending money.

• Wattmeter. It will show you exactly how far you can still count, taking into account the energy consumption. This will allow, if necessary, to change plans, adjust the route of movement. It is advisable to place the device on the steering wheel so that it is constantly in the line of sight.
• Controller. There are several options for such devices. The simplest one, which serves as just a terminal box, is attached anywhere. But many of them are assembled, for example, on microcircuits. Regardless of the chosen solution, it must be borne in mind that all radio components need effective cooling. And this is understandable - the electric / current, passing through the circuit, is partially converted into thermal energy (due to the internal resistance of its elements). This means that it is desirable to place the controller on the frame so that it is better blown by the counter flow. Part of the paint in this area must be removed, and an additional plate of aluminum should be placed, the bottom of which (at the point of contact) is covered with thermal paste.