While it’s nice to be able to fully restore something vintage to its original glory, this is not always possible. There might not be replacement parts available, the economics of restoring it may not make sense, or the damage to parts of it might be too severe. [onyxmember] aka [Minimember Customs] was in this position with an old ’54 Puch Allstate motorcycle frame that he found with no engine, rusty fuel tank, and some other problems, so he did the next best thing to a full restoration. He converted it to electric.
This build uses as much of the original motorcycle frame as possible and [onyxmember] made the choice not to weld anything extra to it. The fuel tank was cut open and as much rust was cleaned from it as possible to make room for the motor controller and other electronics. A hub motor was laced to the rear wheel, and a modern horn and headlight were retrofitted into the original headlight casing. Besides the switches, throttle, and voltmeter, everything else looks original except, of course, the enormous 72V battery hanging off the frame where the engine used to be.
At a power consumption of somewhere between three and five kilowatts, [onyxmember] reports that this bike likely gets somewhere in the range of 55 mph, although he can’t know for sure because it doesn’t have a speedometer. It’s the best use of an old motorcycle frame we can think of, and we also like the ratrod look, but you don’t necessarily need to modify a classic bike for this. A regular dirt bike frame will do just fine.
There’s no better way of improving a project than logging data to make informed decisions on future improvements. When it came to [Brian]’s latest project, an electric bike, he wanted to get as much data as he could from the time he turned it on until the time he was finished riding. He turned to a custom pyBoard-based device (and wrote it up on Hackaday.io), but made it stackable in order to get as much information from his bike as possible.
This isn’t so much an ebike project as it is about a microcontroller platform that can be used as a general purpose device. All of the bike’s controls flow through this device as a logic layer, so everything that can possibly be logged is logged, including the status of the motor and battery at any given moment. This could be used for virtually any project, and the modular nature means that you could scale it up or down based on your specific needs. The device is based on an ARM microcontroller so it has plenty of power, too.
In the ebike world, there are two paths. The first is a homemade kit bike with motors and controllers from China. The second is a prebuilt bike from a manufacturer like Giant, with motors and controllers from China, which will be half as fast and cost three times as much. The choice is obvious, and there are other benefits to taking the first path as well, such as using this equipment which now has an open source firmware option.
The Tong Sheng TSDZ2 drive is popular in the ebike world because it’s an affordable kit motor which has a pedal-assist mode using torque sensors, resulting in a more polished experience. In contrast, other popular kit motors tend to rely on less expensive cadence sensors which are not as smooth or intuitive. This new open source firmware for the TSDZ2 further improves on the ride by improving the motor responsiveness, improving battery efficiency, and opening up the ability to use any of a number of color displays. (More information is available on a separate Wiki.)
If you have a TSDZ2-based ebike it might be time to break out the laptop and get to work installing this firmware. If you’re behind the times and still haven’t figured out that ebikes are one of the best ways to travel, here is the proof you need.
Thanks to [coaxial] for the tip! Photo via Reddit user [PippyLongSausage].
[Tom Stanton] is well-regarded in the maker community, and has put much effort in over the years on a variety of electric vehicle builds. In the process of upgrading his e-bike last year, he ran into some issues with the main drive pulley. Rather than rely on guesswork, he threw engineering at the problem.
The problem concerned the mounting bolts on the pulley’s hub, which would pull out under high torque. [Tom’s] initial finite element simulations had suggested the design was sound, but reality was proving otherwise. After further analysis and testing, [Tom] determined that his analysis hadn’t properly simulated the bolt pull-out condition. With this corrected in the software, it was readily apparent that there simply wasn’t enough material around the bolt holes to hold the torque load.
With the simulation now more closely agreeing with reality, [Tom] was able to correct the design. New parts were created with a strengthened mounting section, and the pulley was successfully able to deal with the loads in service.
It’s a great example of using engineering simulation tools to solve a problem quickly, rather than simply guessing and hoping things will hold up. We’ve seen [Tom]’s work before, too — like this fun backyard trebuchet build. Video after the break.
Electric bikes may be taking the world by storm, but the world itself doesn’t have a single way of regulating ebikes’ use on public roads. Whether or not your ebike is legal to ride on the street or sidewalk where you live depends mostly on… where you live. If you’re lucky enough to live in a place where a bicycle is legally defined as having fewer than four wheels and capable of being powered by a human, though, this interesting bike from Russia might be the best homemade ebike we’ve ever seen. (Video embedded below the break.)
While some of the details of this build might be lost on those of us who do not know any Slavic languages, the video itself shows off the features of this electric vehicle build quite well. It has a custom built frame with two wheels up front, each with its own independent suspension, allowing it to traverse extremely rough terrain with ease even a mountain bike might not be able to achieve. It seems to be powered by a relatively simple rear hub in the single rear wheel, and can probably achieve speeds in the 20 km/h range while holding one passenger and possibly some cargo.
The impressive part of this build isn’t so much the electrification, but rather the suspension components. Anyone looking for an offroad vehicle may be able to take a bit of inspiration from this build. If you’re more interested in the drivetrain, there are plenty of other vehicles that use unique electric drivetrains to check out like this electric boat. And, if you happen to know Russian and see some other interesting details in this build that the native English speakers around here may have missed, leave them in the comments for us.
Ah, the simple pleasures of a bike ride. The rush of the wind past your ears, the gentle click of the derailleurs as you change gears, the malignant whine of the dual electric jet turbines pushing you along. Wait, what?
Yes, it’s a jet bike, and its construction was strictly a case of “Why not?” for [Tech Ingredients]. They recently finished up a jet engine build using a hybrid design with electric ducted fans as compressors and fueled with propane. It was quite a success, and pretty spectacular, but left an embarrassment of riches upon its passing in terms of spare parts. The ducted fans, monstrous 90-mm 12s beasts, along with dual 150A ESCs found their way onto a mountain bike by way of a rear luggage rack. Pannier bags on each side hold the batteries, and a quick control panel went on the handlebar. The video below shows the build details and a couple of test rides, which show just how fast you can go with this setup. It may not be very practical compared to a more traditional hub motor, but it’s nowhere near as cool. Just be sure to wear your hearing protection.
Electric bikes are getting a lot of attention lately. Pretty much anyone can buy a kit online and get a perfectly street legal ride with plenty of range. But if you don’t want to take the kit route, and you’d rather take a tack that will get you noticed more around these parts, take some notes from [Jule553648]’s recent build that definitely isn’t using any parts from a kit.
The motor from the build is an electric power steering pump from a junkyard car. This gets mounted on a one-off rear bike rack and drives the rear tire with help from some gears from a pocket bike gearbox from eBay. A lot of the parts in this build were designed and built using CAD and a machine shop, and the parts for the battery and the power controller were sourced via China to save on cost.
The whole build has a homemade vibe that we find irresistible. The bike can go 35 km/h on level ground without breaking a sweat and has about 40 km of range which is nothing to scoff at. It might even be street legal depending on the wattage of the motor and whether or not you live in Europe (where throttles are generally not allowed on electric bikes). If you’re lacking a machine shop, though, we featured a very well-built kit ebike a while back that you could use as a model to get your feet wet.