DIY Electric Bike Conversion V1

thingiverse

This conversion is still a work in progress, as I continue to build it to fit my bike perfectly. It was inspired by the linked electric bike conversion, and all other parts are custom designed by me to fit my unique bike frame. Solidworks files for the parts that I have available are provided, with more detailed information following soon with schematics and assembly directions. To build this conversion, you will need the following components: Motor: The KD-53-20 Brushless Outrunner 195KV motor from HobbyKing is required. ESC: The Hobby King 80A ESC 4A SBEC is also necessary. Batteries: You'll need a set of batteries such as those available on Amazon under B071HP7ND4. PCB: A PCB like the one available on Amazon under B01N3161JP will be needed. Arduino: An Arduino board such as the one available on Amazon under B0713XK923 is also required. You'll also need 3D printed parts from files, including a HTD5 12T pulley with an 8mm bore for the motor shaft, an HTD5 800x15mm belt, and several bolts and nuts to secure everything in place. This conversion involves multiple stages. It includes custom-designed 3D printed parts to mount the motor hardware, as well as a custom-built controller that displays battery voltage and controls the motor speed from a thumb throttle. The thumb throttle is also mounted on a custom-made holder that allows it to be used on drop bars. Explanation of the files: TensionerBearingSpacer.stl: This file holds bearings on the motor mount, which tensions the belt. MotorMountmotor_side.stl: One side of the motor mount. MotorMountwheel_side.stl: The other side of the motor mount. Battery box upper.STL: One part of the battery box, split into parts for smaller bed sizes. Battery box lower.STL: The second part of the battery box. Battery box top 1.STL: The first part of the battery box lid. Battery box top 2.STL: The second part of the battery box lid. Battery box support.STL: Supports the battery box on the frame of the bike. Throttle holder.STL: An adapter to hold the thumb throttle on drop bars. Motor fan.STL: A fan for the back of the motor. Box bottom.STL: The bottom of the box for electronics and display, with a handlebar mount clamp. Clamp.STL: A clamp for the electronics box on handlebars. Box top.STL: The lid for the electronics/display box. Drive pulley.STL: The drive pulley that mounts on the rear wheel.