DIY Cheap Electric E-Bike Conversion (No Hub Motor Used) Part 1

I converted an old Super Cycles bike into a DIY E-Bike with a few parts. My goal was to be able to do this conversion dirt cheap and without buying a Hub motor kit.
The drive train used a 500w motor, left handed free wheel sprocket and a double sided wheel hub. The idea was to keep the E-Drive Train separate from the pedals incase there is a break down, then I can still pedal home!
Scrap steel was welded to the frame and that was done to hold batteries:
-Link to DIY LiPo Video: • Simple DIY 48V 4s LiPo...
The wiring was all done with 12 gauge braided wire for wires that move and solid core for anything stationary. A cheap engine starter switch was used since it can handle the amps running through it.
---------TEST FOOTAGE PART 2: • Part 2:DIY Cheap Elect...

[@TheDIYMakersManifest]

Test Footage in part 2 : ruclips.net/video/sln55nptPoA/видео.html

[@earthssecretenergy2371]

That,s a great job keep up the good work.

[@mondude9754]

How did you get the hub with a left handed and regular free freewheel? Cool project btw

[@TheDIYMakersManifest]

Hi mondude, thanks for the comment! You are right trying to source lefthanded parts was a nightmare. Turns out BMX bike riders sometimes switch their drive train side to grind rails on the right. This meant I had no issues finding a single speed left handed sprocket, it was the double sided wheel hub that was impossible to source with 2 different threads. What I ended up doing was using the space the double hub gives and rough up the area where I wanted the sprocket with sandpaper and a file. I then used a metal epoxy I've done repairs with that has a high tensile strength and bonded the sprocket on. It worked great! The only issue is you get one shot to do it right since when the epoxy sets it stuck, but I didnt want to weld it since the heat could damage the bearings if I am not careful. My next idea might be to try making my own threads but idk where to source the dies so I might try printing threads and see if it holds. Cheers,

[@earthssecretenergy2371]

These types of motors do not have enough torque to move the bike along with the Ryder

[@TheDIYMakersManifest]

Hi earthssecretenergy I appreciate the concern but rest assured I have had no issues going up hills on it, saves my lazy legs a lot of effort! Although maybe I need to do some more exercise, my hefty body is around 210 lbs (on a good day lol) and the bike im not sure but I will guess 100lbs tops, that would be a total weight of 310lbs.
I cant recall what the torque at stall was on the motor (I want a dyno really bad) I think it was around 2 N.m from the listing which sounds about right for a 500w motor.
Just spit balling the first numbers that pop up on google the coefficient of rolling friction for tire on asphalt is like 0.012, 310lbs is like 1378.95N (the force of the weight) so to get the tire rolling is around (1378/2)*0.012 = 8N. The wheel radius is like 0.3m so the torque needed is 2.4N.m .
So you are correct the motor by itself isnt enough, (2 < 2.4) but the gearing is like 11 teeth to 72 teeth which gives us a total output from the drive train of 13 N.m which is > 2.4 N.m. So even up a bit of a hill its fine (I think you just take the sine of the hill angle to get the components) But I'm not good at dynamics so please correct me if I'm wrong but from using it there's enough torque.

[@Comrade_YG]

Even this is too pricy

[@TheDIYMakersManifest]

Hi Comrade, thanks for the feed back! You are right brand new for everything you honestly are better off just buying something pre-built or a kit. For myself I do some farming on the side and have a lot of scrap parts and junk laying around and figured it would be fun to weld a motor down on an old Canadian Tire super cycles bike. The only thing I needed was the sprockets and volt meter and 25H chain links. Cheers!

[@Comrade_YG]

@@TheDIYMakersManifest i have an old car alternator and I’ve been thinking about turning it into a motor and slapping on my bike but idk how to make the driver for the motor and mount the motor on my bike cuz i have no skills in metal working nor the tools like: angle grinder and welder

[@TheDIYMakersManifest]

@@Comrade_YG That sounds like a really cool idea, I've thought about making a generator out of an old alternator but not as a motor before.
You are right about mounting it was pain since none of this was ever made the fit together and I am a terrible welder so I blew through the thin pipe wall on the bike frame a few times.
For me it just took a lot of screwing around and breaking things to try and learn how to stick 2 pieces of metal together. But if you have the space it's a ton of fun, princess auto and amazon has really cheap tools just be safe, I've burnt myself too many times.