Step 4: Cutting The Swing Arm

The swing arm modification is probably the most challenging part of the metal work. It requires a hole to be cut out of it to make room for the motor. Many people have correctly commented that cutting into the swingarm can seriously weaken it, potentially causing problems. This is partially true, but the final design takes that into account - The placement of the AC motor helps to strengthen and reinforce the swingarm stiffness.

This step requires precision - the motor must sit perfectly in-line with the rear wheel, so that the chain travels straight between them without any flex or twisting caused by misalignment. We used both a square and straight-edge to mark the cut lines with precision.

How fast does it go? How much did the total build cost?
<p>Step 10, wiring- You had 4- 12V batteries in series, could you not have tapped 1 battery for 12 volts? I've tapped 12 volts off one battery in a vehicle that used two 12V batteries in series for a 24Volt system...</p><p>Still a cool project. </p>
<p>See, thats just cool. Nice work.</p>
<p>I been wanting to do something like this for awhile thanks for the Guide!</p><p>I helped with a truck conversion in high school so I'm looking forward to doing all the work my self instead of hardly any. </p>
Out of curiosity would you not have been able to save considerable amount of weight if you had used lithium ion motorcycle batteries? Might even be able to get more connected and extend the range?
you could put a car altanator with a toothed gear on the shaft with very little friction to turn it to charge the extra battery for the light and other normal eletronics on the bike and it should work
Think about it. Even you reduce all the losses associated with driving an alternator to zero,it's the vehicle's drive battery that would be providing any energy an alternator would provided. May as well use the added weight to increase battery capacity
Then how about adding a small diesel generator that can power the motor &amp; load the battery? Instant hybrid motorcycle!
It will add only drag to the system. You can capture some energy through regenerative braking. You add a lot of complexity to your system though.
sorry but i hade to comment on this it maby cleaner but it only goes 30 miles i can do 30 miles on my rebel wich is good old fashion petrol and i can get 180 to 200 miles on a tank <br>surly making the bike electric wouldnt be cost efective as the battarys will cost a lot when they stop holding a charge <br>it seams a bit pointless to me
cant we use something like bicycle dinamo to get the bateries charged?
Actually no. Anything which uses the bike's motion to capture energy is offset by the friction and drag created, so you actually lose more energy this way. Thnaks for the comments!
besides that, the dynamo would have to have it's power converted to DC to charge the battery.
Not that I'm saying a dynamo on an electric vehicle is something that's sensible, but most dynamos output DC without a need of outboard conversion
Dear friends, is it possible to use a car dynamo (without the AC converting part) as an electric motor for a bycicle conversion?<br /> * I could get a used one almost for free; <br /> * a car dynamo weights 12 kg, but some of it could be shaved off (unnecessary handles, installation arms, perhaps - maybe a half kilo or more...).<br />
Yep, easy-peasy. You need a controller for a brushed motor to control the current to the rotor, and a separate controller for a brushless motor to control the current to the stator. The rotor will become magnetically saturated at between 4 and 6 amps (depending on the alternator) so that is a &quot;set it and forget it&quot; part after you measure the magnetic field for peak strength, then it's just a regular brushless motor that runs without drag when you turn off the power to the rotor. The &quot;trick&quot; to getting the most out of the motor is to adjust the rotor current to the lowest setting that still has a saturated rotor, and for that you need that Gauss meter. If you use one that reads low field strength you can still get the relative strength by just looking for how close you can get the meter without pegging it. The further away you have to move the meter the more powerful the magnetic field.
Look for a DC motor Treadmill. These have a fairly strong DC motor. You can find these on the curb on trash day that have little or no use on them.
Friends... I got the answer by myself @ <a href="http://www.4qd.co.uk/serv/appnotes/dynamo.html" rel="nofollow">www.4qd.co.uk/serv/appnotes/dynamo.html</a> . Problem is, the article brings the sobering words &quot;the cheapest way is not always the simplest&quot;. Check it out and count your blessings if you can afford&nbsp;US$500 for an etek motor,&nbsp;and what-not for the batteries... I will keep on looking for a cheap solution! Any suggestions are welcome (my requirements are humble: 50 Km/h, 24 km round trips, mostly level terrain)&nbsp; <h1 style="text-align: center;margin: auto 0.0in;">&nbsp;</h1>
Hi! I liked the instructable a lot as I am researching to embark in a similar adventure; however I found something contradicting: you mention in the parts list that you used a &quot;Perm PMG-132 electric motor&quot; and then mention &quot;We purchased most of the other AC components from Electric Motorsport &quot; but the Perm PMG-132 is a DC motor (I checked!) it is the Perm's edition of the E-Tek, both are DC motors, so you are doing a DC conversion, what AC parts did you need? just asking as I have been researching a lot on the AC vs DC motor debate and your instructable was a good &quot;case-study&quot; for a success story!
Since nobody has replied to your question, the AC parts are the stuff that connects to line power to recharge the batteries. Basically the battery charger is part of the bike instead of external as in many EV. It adds a bit to the weight but also makes charging as easy as finding an outlet while on the road. If you are just using the bike for commuting then you can replace the onboard charger with bigger batteries and a polarized charging plug.
i'd like to note (this instructable is a bit old but still meaningful) that if you're to do this conversion, you have to find motorcycle that uses chain drive. using a belt drive motorcycle will result in not being able to adjust the chain tension as it stretches, prematurely wearing out your chain and sprockets.
Could you use a shaft driven motorcycle? Those dont need to be tightened, all you need is oil for lubrication.
The zip wraps do concern me. During a wreck the plastic will stretch and break the locking tabs on the zip ties. I pick through wrecked cars at junk yards, and I've seen batteries where they shouldn't be.
That's a good concern, and one I considered. Ultimately I weighed all the aspects of those zipties vs. metal, which I had in the original design. The weight savings is huge, the ties are remarkably strong, and the batteries are wedged in so tight, with lots of thick battery cabling too boot, that they don't come out easily, even when I want them out. And with a top speed of about 35-40 mph, if I'm in a wreck that has enough force to knock those batteries out of whack.... well then I've probably got a lot of problems to deal with. Thanks again for the comments, Best.
That's true. Your going to have problems at 40 mph. But it's best to minimize them. Remeber the important equation is:<br/><br/>Force = Mass + Acceleration<br/><br/>The best way to think of it is that a static force has no change in acceleration. But even a slight difference in acceleration leads to a huge change in force. You can hang on a tree with shoe strings, but the moment you try to swing into the local swimmin' hole you'll find yourself in a great deal of pain. <br/><br/>That change in acceleration is the important part. That's why bicycle and motor helmets seem hard, but in reality they slightly slow the rate of acceleration.<br/><br/>Just being a math and safety dork all at once. I've cracked three helmets with nary a car in sight. All my fault :-(<br/>
Force = Mass X Acceleration.
... um.. mr. math and safety dork (i am a bit of one myself)... <br><br>force = mass &quot;X&quot; acceleration...<br><br>maybe hop off your soapbox and check your formulas...<br><br>-CW
hey its a good job done by you<br>i need some help from you because you are a expert<br>please do me some help<br>i want some knowledge about this so please contact me at my mail id please<br><br> raju4love1u@gmail.com<br><br><br>pls please do me this help please please<br>
Wahhh! I used to have a Rebel hard to believe it was almost 25 years ago nice little bike and the conversion looks kool too how fast/far can you travel on it?
great job i wish yo can put more instructions about how connect the controller and the engine, and whta happen with the Throttle?(how it will work ?)<br> as well as WHAT HAPPEN WITH THE BRAKES?<br>in resume :can you put a BLOG and a STEP by STEP method?<br>(under our own risk)<br>thanks! great job
sparkyrust; thanks for posting this! <br> <br>For those who have done this conversion: have you tried the Optima Blue Top battery; and converting headlamp/tail lamp/directional lamps to LED bulbs?
Has anyone considered using a HYDRAULIC (think Hydrostatic) drive with an Electric motor?<br> <br> No drive alignment issues, just hoses, a pump and the Hydro motor<br> <br> See <a href="http://www.hydraulicinnovations.com ">www.hydraulicinnovations.com </a>for details. Their unit is larger and heavier duty than this project would require, but the concept&nbsp;would be&nbsp;the same.
Hey guys here is just a little comment to think about. Hydrogen has been the &quot;fuel of the future&quot; for 45 years. And always will be. Forget your hydrogen powered whatever. There is no feasible way to, A; Compress the hydrogen enough to get a reasonable energy return per fill up, and B: no way to completely seal up any container of hydrogen. Tiny slippery little molecules just will not stay in the jar.And C: Anyone remember Lakehurst Field and the Hindenburg? A pleasant fantasy, a car the just makes water when you drive. Time to wake up now
Hindenburg disaster was not caused by hydrogen. The myth that it was has been tackled and disproven many times over. It was a combination of the chemica treatment it got and the aluminium covering. If hydrogen was burning in the video, we would not have seen the flames and smoke that we did. The hydrogen can be seen burning after the fact, but that was long after the accelerated due to the chemical treatment on the blimp.
Im wondering whatever happened to Hondas car Clarity that ran on hydrogen :P
Man, you gotta psot a video going 0 to top speed, that bikle looks sick
great work....<br>
i fly r/c planes, the prices of lipo batteries has come down dramatically. I<br>get mine from china.<br>http://www.hobbyking.com/hobbyking/store/uh_listCategoriesAndProducts.asp?catname=20C+Discharge&amp;idCategory=239&amp;ParentCat=85<br> i fly 24 volt brushless motor setups, these batteries can offer much greater power to weight ratio. They do require special chargers and cannot be discharged below 3 volts per cell. but lead acid shouldn't be deep cycled either. just an option.<br> i always use paypal, especially overseas orders.
Hubiewan asks:<br /> Why not use the original gas tank to store the electronics, thus keeping it looking like a regular bike?
i agree because then you could fit the other batteries up front and then you could have real side bags for runs to the store and could store the charging cord in the gas flap
I want people to look at mine and say, &quot;That's not a regular bike.&quot; Therefore, when I make my ebike, the design is going to be based on the components it uses, which is how the design of gasoline motorcycles arose.
<strong>Hi<br /> Whatll be a good ratio for a bike weighing app. 120 kgs + a 70 kg rider?<br /> Anji</strong>
I built a similar project last summer. You can see my basic web page about it at <a rel="nofollow" href="http://web.mac.com/benhdvideoguy/cycle/Welcome.html">Ben's Electric Motorcycle</a><br/><br/>Mine kept the gas tank for looks, and it works as a cover for the charger.<br/><div style="margin-left:15px;"> <object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/Ujydj6SBfxM"></param><param name="wmode" value="transparent"></param><embed src="http://www.youtube.com/v/Ujydj6SBfxM" type="application/x-shockwave-flash" width="425" height="344" wmode="transparent"></embed></object></div><br/><br/>Great job on yours Sparkyrust!<br/><br/>
Heres the thing about electric.In the wrong hands it more dangerous to the environment. People will not recycle batterys but toss them in landfills. Electric is only good in the hands of private builders like you and me . People who know where to take them/use them and recharge them Right. It not worth the money to invest in electric bikes/cars till we get better Battery cells which can produce the power we need to make the vehicles run a longer distance at leat 250 miles.Hydrogen is the wave of the future.
I&nbsp;have a friend who loves going to the landfills and getting the car batteries that people leave. Puts them on a desulfator and brings them back to life. He gets a truly dead battery from time to time, but its pretty rare.<br />

About This Instructable




Bio: Marque Cornblatt was born in Baltimore, Maryland and now lives in San Francisco. He holds an MFA in Conceptual Arts from SFSU; has a diploma ... More »
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