This project was developed by students from 12th of a vocational Course of Computer Maintenance at EPFelgueiras (Portugal), as part of PAP project under my orientation. The goal was to build an electric bike under European legal rools but with a good performance and autonomy that could be used daily in a frequent up and downhill area, not realy appellative for bikes uses. Half year after, dinabike as over 2600 Km (1600 Miles) with no problems at all, except for regular maintenance: brakes, tires and a few tunings.
Step 1: Stator Windings
We began by the stator building a gadget to do the copper winding.
For a correct placement of the coils we designed and cut with a computerized milling cutter a polyester mold as shown in the picture.