Instructables

I live about 10 miles away from my job which meant I was using about a gallon of gas a day just to get to and from work. I figured there had to be a better way. I looked at electric bikes and conversion kits but the cost was way more than I wanted to pay. Then there was the 49cc 2-stroke conversion kits. I found these as cheap as $140 but wasn't really sold on the idea of altering the bike so much. Then I remembered the "Stinger" from my childhood. These were friction drives we bolted to the back of our bikes. I started doing a little searching and found friction bikes of all kinds on YouTube. These were various motors mounted to the back of the bike with a peg on the output shaft making constant contact with the tire. This meant that every time you stopped the bike you would have to restart the motor. If something happened to the motor you would have to get off and adjust a turnbuckle to ride the bike normally. I wanted to ride the bike powered or un-powered at any time and not have to restart the motor every time I stopped. So after watching countless videos I came up with my own idea. I would incorporate some kind of clutch system in my friction bike. Presented here is what I came up with. Unfortunately I failed to take pictures during the build so I only have pictures from the finished project. By the time you finish this instructable you should have a good enough understanding of the concept to build one yourself. If you already have a bike and a motor and do some salvaging you should be able to complete this for around $50. Here is what I used:

GMC Denali 700c Road Bike

26cc Weed Wacker Motor

Schwinn Seat Tube Bike Rike

1 x Sunlite ATB Shift/Brake Lever Set - 1 Pair, 3x7-speed, 2 to 1, Black

1 x Tektro RX 4.1 Reverse Brake Levers Black

Bell Shift Cable Kit

1/2" Aluminum "U" Channel

1/8" x 1" Aluminum Flat Bar

Misc. Nuts, Bolts, and Spacer (I used all stainless steel but you can you what you have}

1/2" Plywood (A piece of scrap)

Spring

Cable Clamp (Salvaged from another bike)

Turnbuckle

Drill

Saw

Wrenches

Tape Measure

 
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Rarnd4 months ago

This is a great little instructable and very clever :) However I have to warn people (for the UK at least but I believe the laws are similar in the USA?)

Any bike that is powered / power assisted with gas/petrol requires you to have a drivers licence (for a motorbike), for you to wear a crash helmet (technically anyway), and to have a licence plate, insurance and tax.

Basically, any conversions that involve high voltage (>250w in eu, >750w in usa) or gas/petrol will be treated as a moped/motorbike, which will increase the costs significantly; and gives the police the right to confiscate your bike on the spot if you cannot produce the relevant documents.

I'm not trying to knock this instructable because it is really really cool, as well as shockingly cheap, I'm just warning people. I'm trying to get an electric bike myself and I've had to do a lot of research into the laws around them. It sucks.

Thank you for sharing this instructable anyway :)

ALTAMIRA Rarnd3 months ago

Sorry to say but I don't know where you got the idea that the laws are similar une UK and US ??

The truth is that the laws in are much more different you might think ! In the US they pretty much can do what they can do in term of custom bikes. Under 49cc, it's considered a moped; no drivers licence, no licence plate, nada !

Rarnd ALTAMIRA3 months ago

When I said that "I believe the laws are similar" I mean't it in the fact that both areas have restrictions on wattage and gas/petrol limits.

If you read my entire comment, you can see that I mention the differences between the EU and USA when it comes to wattage (250 vs 750).

When I say that they have "similar" laws, it means that they both have laws revolving electric bikes, both having restrictions on the same types of things. The severity of the restrictions, however, is dependant on each location. The USA, while having far more loose restrictions on electric bikes, do still have restrictions before they are considered motor-bikes and require driving licences to use. They can not do pretty much anything, they can just do more than the UK/EU, for example.

I hope that clears things up.

ContraptionMaker (author)  Rarnd4 months ago
Thanks Rarnd, and yes, you are right, everyone should check their local laws as they are different depending on where you live. Here in Illinois, USA, you only need to be a licensed automobile driver, the motor must be less than 50cc, cannot reach over 30mph in a one mile stretch, and cannot have a transmission that lets you change gears. No tags or insurance required. There is no helmet laws in IL for motorcycles or bicycles. As far as E-Bikes go, anything goes there. We can have 6000w on our bike, as long as it is electric only and has pedals, there is no restriction, unless of course it is an electric motorcycle then the rules are the same as any other cycle. Again, these are IL laws and yours will probably be different.
Wow, you have some really loose regulations in IL! I wish I lived there.

In the UK, you cannot have a bike that has more than 250w of power, it must have pedals, and it cannot exceed 15.5mph on full-electric.

Anything more than that, or anything with petrol at all, is considered a motorbike and you have to have documentation, helmets, etc. etc.

Talk about fun-police! Thanks for the comment though, always nice to learn about how the laws differ and such :)
ContraptionMaker (author)  Rarnd4 months ago

*always nice to learn about how the laws differ and such*

That's what Instructables is all about, LEARNING! :)

nlane64 months ago

ContraptionMaker, thanks for sharing your creation with us. I've been trying to figure out how to make a similar motor mount. I was thinking the rear support bars would need to be on opposite sides of the wheel, I've been working for weeks on this but it never works (the spindle keeps riding off the wheel). You have brought forth a great new idea, place the mounts only on the left side and have the rear support act as a guide rail for the clutch action. Out of the box thinking for the win!

As for troll-people like solsmac, they do not understand. This guy probably doesn't ride long-distances, and thinks his muscles are made of titanium. You will probably never get to race him and his pedal power, but if you did, my money's on the 2-stroke!

True, this project is not going to change the world. But I'm sure it has already made your life better.

ContraptionMaker (author)  nlane64 months ago

Yes it has. I love to ride but my knees can't take the peddling anymore. I hope you do a structable on your bike. I'm glad I could inspire you.

Rarnd, You only need a drivers license ,license plate... If its above 50cc's, but not sure if you need a helmet i assume it depends on the state you live in.

Just though id clear that up.

This is awesome great clutch design I think I might attempt this
ContraptionMaker (author)  thataudi4000cs4 months ago

Glad I could inspire you, hope you'll create an Instructable, can't wait to see your progress and what you do with it.

I love that you can just get up and go, you don't have to jump off and mess with a pull cord. (BTW can i say i hate pull cords!)

ContraptionMaker (author)  tisaconundrum4 months ago

HaHa! Me too!

loganrt114 months ago
That's pretty awesome
ContraptionMaker (author)  loganrt114 months ago

Thanks

chessman1224 months ago
Like your bike dude. Does it ride smoothly.
ContraptionMaker (author)  chessman1224 months ago

Thanks, glad you like it. It rides very smoothly. It's just like riding the bike without the motor, just faster, and best of all, very little peddling!

amulder14 months ago
love the old solex bikes we have here, rode one a while back. Those are just awesome! Bit odd in the beginning, always riding full throttle and no clutch....
ContraptionMaker (author)  amulder14 months ago

Ya, that sounds a little dangerous...

doodlecraft4 months ago

Wow, super cool! :)

ContraptionMaker (author)  doodlecraft4 months ago

Thank you!

Thats a great project looks like a pile of fun. If you go for the four stroke, the six to one gear box in the photo will bolt straight on to a 35cc Honda.

http://www.scooterpartsrus.com/49cc_gear_box.htm

Screenshot from 2014-07-06 20:48:24.png
ContraptionMaker (author)  liquidhandwash4 months ago

Thanks for the info. Think I'm going for a belt drive with the 4-stoke.

You can also convert it to propane. I do all my lawn mower a this way. good plans liked it alot....
TFS Jake4 months ago
http://www.gomeyer.com/rc-cars-scooters/goped-clutch-kit-54mm-p-435.html this is what you want.
Gregbot4 months ago

Sweet!

ContraptionMaker (author)  Gregbot4 months ago

Thanks, glad you like it!

solsmac4 months ago
But it's still cool!
ContraptionMaker (author)  solsmac4 months ago

Thanks!

jleslie484 months ago

wait a minute, how do you start it? my weed whacker and a pull rope to start it and it doesn't look like to me that that is how you are starting your motor. It seem to me you are starting in more like how you would push start a manual car: get the bike up to some kind of speed, "pop the clutch" and the engagement of the clutch wheel against the tire spins the motor and starts it that way. Is that what is happening?

ContraptionMaker (author)  jleslie484 months ago

Yes that is exactly what is happening. I only need to get to about 5 mph. I pull the lever, the motor spins against the wheel, and it starts. No pull start required.