Build an Electric Motorcycle on a budget

Step 1 What you need

Here is a list of what you will need and how to find it:

A Plan: This is the best question to ask yourself before going out and buying anything.
How far, how fast, how much? To get a good idea of this, spend some time on: http://www.evalbum.com/type/MTCY - its got 1000's of Electric Motorcycle conversions with pictures of the bikes and the components used to make them.

1.Donor Motorcycle or a rolling chassis - Check Ebay and Craigslist. Personally, I like to set up an RSS feed from my craigslist search, otherwise I browse for way to long when my ADD kicks in. I found my 1967 Honda Dream(ca160) on craigslist for $275, with frozen motor, but hey, I don't need that anyway.

2. Electric motor - There are lots of options out there, but I recommend a Brushed 48v Etek Briggs and Stration due to its price, power, and availability on eBay. The original is no longer in production so your options are to buy a used motor or get a clone. Also, if you have a local golf shop go talk to someone there - they are gear-heads too! These guys will like you and they will like your project. So see if they can cut you a deal on an electric motor, there will be plenty of just sitting around.

3. Batteries again, consult your plan. My plan was 30+ range, so I picked up some deep cycle batteries at walmart for $62 a piece. They are 12v 105 aH. Looking back, I wish I would have gone with some smaller and lighter batteries. I really don't need the amount of range these current deep cycle batteries provide.

4. A motor controller that delivers/regulates the energy from the battery to the motor. Think of this as a transmission. I found a Curtis 48volt 300 amp controller on eBay for $150.

5. A twist grip throttle that sends an electric signal to the controller - which determines how much energy is sent to the motor from the batteries. Most popular is the Magura Twist grip, available on ebay.

6. A battery charger to re-charge your batteries for continual (cyclic) use. I am still working on finding the best charger for my ride, but I would like to do something that could be out on board.

7. A high-current switch or Contact Buy this on eBay or at a Golf Cart shop. This part makes the loud "click" sound when your turn on a golf cart.

8. A high-current fuse to limit the amount of energy drawn from the batteries in case of a short/failure. Typically = to Control max amperage. I got a 2 300amp fuses on eBay for $19 bucks

9. A large gear ratio to reduce the amount of current required when accelerating (this can be accomplished with a large custom rear sprocket and a small front gear/pinion on the motor). My current gear ratio is 3:1, optimal would be 4:1+

Optional stuff: instrumentation, speedo, ammeter, or a way to judge batteries state of charge.

Comments

[kaplag]

I bet spellcheck corrected contactor to contrator, but it really is high current contactor. The closest thing to a high current contractor is my dad    : ]

[joecapillo]

I like the craigslist recommendation. You can also try posting to the "wanted" section on cl advertising for a non running bike that has wheels, brakes, tires, etc... intact and that you can only pay under $300. I did this and the same day had five bikes to choose from!