Building an Electric Cargo Bike with Cable Steering and Full Suspension
HTML-код
- Опубликовано: 10 июл 2024
- After many months of planning, building, shooting and editing I can finally show you my most ambitious bike related project yet. I planned this new Cargo E-Bike as my personal dream bike so it's packed with many new features like electric assist, cable steering, integrated wiring, full suspension, a new kickstand and more.
This series will consist of 2 build videos and one follow-up video with additional content. Enjoy!
00:00 Intro & Concept
02:25 Preparing the Donor Frame
05:00 Frame Jig, Tooling and preparing Tubing
07:03 Cutting/Mitering/Drilling Frame Tubes
15:20 Turning Custom Headtube
18:00 Welding the Frame
23:28 Checking and Fixing Distortion
25:05 Cutting, Mitering, Welding Cargo Cage Parts
29:43 Building a Fixture & Mitering Cargo Cage
34:04 More Fixturing
35:30 Building Lower Cargo Cage & Tack Welding
41:53 Finishing Frame Welds & Outro
🔧 LINK LIST for tools I use in my videos:
hero.page/philvandelay/my-fav...
LINKS:
📐 PLANS: www.etsy.com/listing/1497977778
👕 SHIRTS / Merch Store: phil-vandelay.creator-spring....
🙏🏻 Patreon: / philvandelay
📷 Instagram: / phil_vandelay
Easy DIY Cargo Bike Build: • How to Build a DIY Car... 
Наука
You are the undisputed best.
This is amazing! Brilliant work! I’m sure that documenting this build doubled or tripled the time and effort it took to complete. Thanks for sharing.
You may not have an engineering degree but you are definitely an engineer.
Great work.
dang i have the degree, but i dont have the skills, nor the patience to build something like this, he's a great engineer!
Yes, when Phil said ‘I am not an engineer’ I thought, well you certainly have the mind and skill of one!
Engineering is a mindset, not a skillset.
@@badsamaritan8223 I think it's both, and he definetly doesn't lack any of this two. Also, as a recently graduated engineer, i really think that for some people there is no need to go to uni to learn the skills or get this type of mindset.
I would disagree, he is an amazing designer and fabricator, but there is a lot more to engineering than just making something. To "engineer" this bike he would have to create requirement and analyze his design against them.
Why use aluminum tubing and not steel or titanium?
Why did he use 55mm tubing, what about 45mm? 50mm? 60mm?
What set the size of the cargo space? Did he asses the common objects that he is likely to carry? How does he know that this design will support their weight?
Why choose this wheel base? He said it has a smaller turning radius, but how small should it be? Is there a target?
I am not trying to dunk on his design or project, its extremely high quality. I am also not trying to say that he should have assessed the questions above. What I am trying to get across is that engineering is about defining goals, setting requirements that enforce those goals and assessing design decisions against those requirements. Engineering is not about making something, it is about creating the optimal design for your specified design criteria.
The engineering of the fixtures and using the table as a frame jig is the most impressive to me.
Right? So much of the work of assembling and welding something is the time you spend perfecting the clamping setup and the jigs. I've always thought welding was 95% prep work and then the last twentieth bit of time you actually join the metal together.
The part where you drill the Holes 37:45 - really makes sense. I never thought about it that far. You definitely want to have even a pin hole for just gas expansion
Nevermind the bike. That workshop and that space.... and the jigs and tools... amazing work!
Fantastic. As a proud builder and regular user of your previous generation cargo bike I’m sure I can recommend the very careful and complete plans even without buying them! Indeed if, like me, someone is enthused by this but lacks a fixture table or milling machine - the original design is a great “learn to weld” project. Thanks for the inspiration Phil.
RUclips suggestions are usually trash. But sometimes you just come across gold. Subbed
That table and the kit youve made for it all is mindblowing. Fantastic craftmanship
That's by far the best and most professional DIY cargo bike builds.
A damn good job!
Makes my and all the other builds here on YT look like crap.
I feel like I'm in high school looking at all your equipment and I've been a mechanic for 20 years. You're an inspiration.
That’s legit some of the best welding videography I’ve ever seen. Really close in and I can see what you’re doing clearly
I re-watch your original build vid a few times a year, and one day soon I and going to attempt to build one for myself, I just need to commit :) I would also like to comment that, yes, I would like to see other vids on how you make and use the jigs, it's all excellent info, thanks!
Amazing precision engineering🤯🍻
I have been self declared a super fan of your design. I find it so smart, elegant, light, logic... congratulations, really.
amazing creation!
Definitely didn’t expect to see you here 😄
CHRIST ON A BIKE!!
*Hell:* the constant pain/regret related to a *fully informed accusing conscience* that stems from willfully mocking/rejecting God: Jesus Christ. A common choice re: those headed to an eternity w/o God-those not willing to live a life of obedience by faith b/c it's just too inconvenient to the lifestyles they want to live.
Honestly I'm a danish welder and your welds are nothing to be shy about. But I would suggest a little tip. Like when you have support under the "foot/cargo panel" aka. The only square thing 😂 and this trick can be used on tubes as well. Don't butt up the support all the way to the thing you are welding against. Leave about 1 or 2 cm (deepening on the cup) so you can make a tack weld "almost" under.. (so you get to tack in four places) always try to make contra racks and weld to avoid distortion. Hope it helps you. And what a beautiful video and build! Great work !
One tip that I learned from a bike builder when welding my own frame was to spread the heat around the tube when welding. For example, if your first tack is at 12 o'clock, only lay down a bead about 10-15mm long, then move to the 6 o'clock position and lay down the same length bead. The material will tend to distort in the direction of the heat so spreading it out in this way helps "pull" the material more evenly around the weld. Great video! Thanks for sharing!
Yeah this helps a lot, I do it whenever possible
fireball tools made a great video showing how useful a fixture table is, he sent plans to three different fabrication shops and they were all out of spec, then he had his video editor do it with the fixture table and he nailed it despite not being a welder or machinist
Definitely, the table is one of the best tools I ever bought
This dude added just enough motion blur on to the scrolling plan footage that it's impossible to really see anything. 40€ for the plans seems like a fair deal, provided they're perfect.
Holy cow, that's what I have been waiting for.
awesome build and love your bikes.
The flash from welding may not be as bright as it really is in real life but the difference in scene brightness can be straining to people with bad eyes.
I personally appreciate you filming through the welding screen. (in his last video, Brian Oltrogge used a reactive welding screen [clear light 2.0] that he printed an adapter to fit to his camera to reduce the sensor blowout) thought it was really nifty.
The whole project is great, but that jig table and setup is beautiful!
That is awesome! Really looking forward to Part 2!
Also, there is nothing wrong at all with your welds! I've seen many 'professional' welders not lay a bead anywhere near as good as yours.
Thank you RUclips for recommending this video to me. What an amazing project to see. Really enjoyed watching your skills. (And thank you for protecting my eyes from the harmful light levels of my screen during the welding shots 😉)
Chopping up perfectly good bikes to make a perfectly great bike
Really appreciate the welding filter 😌
I really appreciate the welding goggles for the camera. obviously a computer screen can't blind anyone but I do find the welding sometimes too bright and just annoying so I look away. this was great though.
On the light being blinding, it is in a way blinding for me as I tend to watch videos in dark environments and my PC lives in dark mode so when the arc is struck and the full spectrum of light is blasted out, it makes my screen go from zero to hero real fast and with my eyes adjusted to essentially a twilight to daylight. With the green filter, it makes it so that we can actually see the arc, the bead, and the progress of the weld which is to me far more interesting.
That little quibble aside, that is a fantastic bike design and looks like a helluva project and when it's done right... *chef kiss* Ooh it looks so good...
Yeah I understand the point about screens in the dark but believe it or not, I've actually had numerous people who believed they were getting "Arc-Eye" from looking at the welding on screen
For your videos I would like to have the option not only to like it but also to mark it as "valuable content" or so. You are not alone with this but I head this thought especially yesterday while watching it.
Ah, that is a beautiful thing to watch. I hope it brings you great pleasure - it did for me! Looking forward to the next videos, thank you.
40:30 -that was the most beautiful 15 seconds of machinery. It felt like a samurai film.
Personally, your welds look beautiful. I have performed welding on aluminum to a very limited extent (it was over 20 years ago). Your points about the 'optimum' settings are correct, in my opinion. Practicing your own technique, or developing one based upon welding fundamentals, is what will serve you in producing consistent, high quality welds. And, being self-taught is one of the best ways to learn from my experience thus far. You have to do it to become better--practice. The design of this version 2.0 bike is really nice. I admire the thought you put into your design and more importantly, your support equipment to make your fabrication easier. Your weld table, the super-jig, tubular blocks and the other tools you made are all ingredients in the recipe for success. Thanks for sharing your idea, thought process, fabrication technique and skills for the inquisitive minds out here in the design/tinker RUclips community. This video was worth the wait. Excellent job!
Thanks for the elaborate comment!
I always flinch when a welder sparks an arc. Even when it's in a RUclips video. There is no risk to the eyes watching a video of an arc welder. You'll never get eye damage from an LCD screen unless you're always staring at it.
Babe wake up Phil Vandelay finally built another cargo bike!!! ❤
Hi, thanks for the detailed videos. A video discussing the considerations for the donor bike would be greatly be appreciated, thanks!
There's only a few channels I can watch nowadays. Channels like Phil Vandelay and My Mechanics. Once you have seen the overkill precision and detailing, it cannot be unseen. You can not enjoy the average videos after these as you used to.
Thanks for making these videos and giving us new dreams and goals.
Sir, because of you, I've created my first cargobike out of my garage, with no prior experience in welding or bike build in general..... I thank you for that
A well deserved like, for an amazing job. This video shows how useful are fixture tables.
You make good use of your table. I see so many fabricators too prideful to keep references and rely merely on a tape measure. You do amazing precise work.
Always amazed by how much from project to project you improve your skillset. Great job as usual Phil. Liebe Grüße aus Berlin
Am I going to build one of these? No. Am I looking forward to the remaining videos anyway? You bet I am!
Absolutely love this. So envious of that bike.
I have adopted my (orphaned) 12 yo grandson and your channel is perfect for his desire to build things.
I purposefully set pt 1 aside with the intention of watching pt 1 and pt 2 together-so far it was a good decision
but I'm not surprised. I haven't been disappointed since I found your channel and began watching. *Well done.*
I was literally thinking yesterday when you were going to drop another video.
Just finished watching the video. F**** awesome!!!!
I have so much tool-envy right now
I watch many welding/building videos on YT, but your idea with the filter is great, now I can see what you are really doing.
can't wait for the next episode 👍🏻
I'm blown away--amazing! I ride a Surly long tail cargo bike and this is next level x 10!
Phil is baaaaaaaaack!
21:03 I love the green filter
Fantastic, really nice capture of the whole process!
Now to transfer this idea to an electric endro motorcycle, this is road ready. Awesome build, keep it up! Wax on, wax off!
Always enjoy watching your builds and appreciate both the workmanship and the thought process behind your solutions to problems. Looking forward to parts 2 and 3!
Best documented build video, well done
I love the cable steering.
Es muss man auf die Idee kommen 😁👍 ihr seid mega cool 😎
Full suspension, great!
cannot be more impressed. awesome!
As always a super nice build. Can't wait to see the next episode!
Really liked the up close filtered view of the welding. Never seen that before. Thanks.
Absolutely amazing!
Nice Work! I love the welding shots...
Absolutely fantastic! Your progress from your humble beginnings with a flux core on your kitchen table is phenomenal!
Never seen this kind of precise work. Good job. Thanks
Just Bloody amazing!!!
This looks incredibly sick. I've been looking forward to this ever since you teased it on instagram. Incredible job!
It's incredibly satisfying to watch it all come together, and inspiring on a personal level as well. I'll be looking out for the next one for sure. Thank you for sharing the build!
Brilliant work.
You're a class act, Phil. thanks for this, it was a really enjoyable watch.
Beautiful work as always! Well done.
Awesome! Great job!
Best video on custom bike making that i have ever seen. Wonderful work. Thank you for posting.
Outstanding as always 👍
Wow, can’t wait to see the rest. Bravo!
The filter over the camera for the welding shots was a stroke of genius
Never saw so great job before! Thanks a lot.
Great work, cant wait for the next videos!!!
Nice work👌 really enjoy your videos. Calm, informative and gute deutsche Handarbeit 😄
Exactly what I needed!
This is so dope!
Beautiful metal work, and the photography is second to none 👌
Cool Project! Looking forward to the future parts!
Superb Phil. Absolutely superb.
Beautiful precision and organisation. Excellent work.
This is so sick! Both the explanation and the build! Mega !
Phil - amazing work as usual. Love your videos
amazing work as always! subtly one of the funniest people on youtube!
That is a beautiful headtube. Thank you for the video
Awesome ❤!!
Amazing job
Hypnotic, such skill
YOU ARE CRAZY! I love you work!
So cool project!
Better than Netflix, thank's Phil!!
Nice work!
Amazing build, well done
So good! Love your humour splashed in throughout as well. :)
Great video, reminds me of watching my grandfather build dental equipment in his workshop with his lathe and self made tools. Very satisfying.