Introduction: Greg's Electric Powered Bicycle Trailer

Electric Bicycle Trailer
 Powered by an electric motor and batteries, this trailer pushes a bicycle around. A gear shift mounts to the handlebars so the rider can select the proper gear on the trailer wheel to get up hills or control speed. The motor is also turned on and off from the gear shift. The frame is a wire basket and aluminum angle stock.

 The batteries can be recharged with a standard 12 volt automobile battery charger or other 12 volt chargers. There are no electronic parts. Other containers can be used in place of the wire basket. a piece of extention ladder can also be used for a frame.

Full Permissions granted from Greg
as Greg doesn't do internet I am posting for him 

Step 1: Specifications

Top speed - 19 mph with mountain bike, 23 mph with road bike
Range - 12 miles/battery 17 amp hr., up to 4 batteries (48 miles)
Weight - 30 lbs. without batteries
Cargo Capacity - 100 lbs with 4 batteries, more with fewer batteries
Projected cost of materials- $ 850.00 US

**Bicycle Trailer - non motorized

 A high quality bicycle trailer can be made using a peice of extension ladder or aluminum angle stock. Containers of various types can be bolted to the trailer top for hauling cargo.
Specifications
Weight - 15 lbs.
Cargo Capacity - 150 lbs.
Projected cost of materials - $ 220.00 US

Step 2: Bicycle Trailer Notes

To bend arm - Notch blank as shown, heat bend area with torch before bending to prevent cracking.
Batteries- One large battery is cheaper than multiple smaller ones. Multiple smaller batteries allow you to use only the number needed for a particular trip and carry less weight for short trips.
Batteries can be mounted under the trailer with nylon straps.
Place battery on drive wheel side for traction.
Do not leave discharged batteries in freezing temperatures.
Downshift completely to turn motor off.
If circuit breaker trips (motor stops) down shift one gear to shut off switch then up shift and motor will start. Breaker automatically resets by shutting off power.
Use made in U.S.A. parts whenever possible. Avoid Chinese motors and gear boxes.
Overloading motor can cause motor to overheat and fail. Downshift or pedal harder to reduce motor load.
Motor brushes will need to be replaced occasionally. They are rated for 300 hours of use. They are easy and inexpensive to replace. Mount motor so that brushes are acessable.

 

Step 3: Parts List

Z2 Bicycle Trailer
Item # Quantity Req'd Stock Bicycle Parts ( * for non motorized kit )
1 * 2 rims, 20 x 1 3/8 36 hole, shrader valve
2 * 2 tires, 20 x 1 3/8
3 * 2 tubes, 20 x 1 3/8 shrader valve
4 * 72 Spokes and nipples
5 * 2 rimstrips
6 * or items 1-5 plus 14 & 15 (hubs) completely assembled
    please specify if you wish a different tire and tube width
7 1 freewheel, 35 mm x 1.0 threade, 6-speed, 13-34 teeth
8 1 chain with master link
9 1 derailleur
10 1 shift lever, 7-speed
11 1 shifter cable and housing, please specify longer length for recumbents
12 1 spokeguard
13 * 1 wirebasket

Item # Quantity Req'd Custom Machined Parts ( * for non motorized kit )
14 *x2 1 non threaded hub with sealed bearings
15 1 threaded hub with sealed bearings
16 * 1 axle, specify frame width
17 1 derailleur hanger
18 1 axle shim
19 1 drive sprocket, # 41, 12 tooth, 3/4" bore, must modify to fit narrow chain

Item # Quantity Req'd Aluminum ( * for non motorized kit )
44 * 1 1/8 x 2 x 2 aluminum angle, sharp corner, 6063, 8' long, frame
45 * 1 1/8 x 1 x 1 aluminum angle, sharp corner, 6063, 6' long min., towing arm

Item # Quantity Req'd Stock Parts ( * for non motorized kit )
20 * 2 axle bolts, 12 mm x 1.75 x 110 mm, grade 10.9
21 * 2 u-bolts with nuts
22 1 gear motor, 12 volt, 1/6 h.p., 360 rpm
23 1 to 4 batteries, gel cell, 12 volt, 17 or 32 amp hr., deep cycle
24 1 main on/off switch, toggle
25 1 shift cable on/off switch, toggle on/momentary off, (must be modified)
26 24 1/8 x 3/8 stainless steel pop. rivets
27 4 1/4 20 X 5/8 hex hd. bolts and nuts, grade 8
28 11 # 10 - 32 x 3/8 hex hd. bolt grade 8, for rear motor support, and tab washers
29 1 shrink tubing 12" long
30 4 cable ties, nylon
31 4 reusable cable ties
32 1 wing belt, for shifter
33 1 curcuit breaker, 12 volt, 40 amp, auto reset
34 6 wire eyes (for 1 battery, order 4 more for every additional battery)
35 * 2 rod ends, 5/16 dia.
36 * 1 hitch pin clip
37 * 1 5/16 - 18 x 1 1/2" bolt, grad 8, fully threaded
38 * 6 5/16 - 18 hex nuts
39 2 nylon webbing straps (to secure batteries) 2 per battery, 30" long
40 1 battery charger, 12 volt (optional)
41 1 spring for shift cable switch
42 10 tab washers, for fastening basket to frame
43 10 #10 - 32 hex nuts







  

Step 4: Diagrams

Heres the Rest of the Diagrams from Greg, I'll see if he can do a real step by step guide
Next I'll upload his Electric Bike plans, hope some of you can build this and even do a better guide

-RodneyLee

Comments

author
f1dd13r (author)2016-10-17

Interesting. I think it would be cool to have this lighter and just use the trailer to actually charge a 12 volt battery instead. I made one of those static bike chargers with my bike and a trainer stand and a motor but it is quite boring just pedalling and pedalling stuck in one place. Being able to just go about daily bicycle rides and charge a battery would be so much less dull.

author
BillBiker (author)2011-01-22

As Pickpacket said dangerous, BUT if it used a better hitch system like I saw on another 'able it would be fine for high speeds ;) ! What really got my interested and tickled my brain muscles was the derailler and freewheel! Really cool!

author
karossii (author)2010-09-07

Very interesting; but it feels like an incomplete 'ible. Looking forward to the 'real step by step guide' you mentioned in step 4.

author
BobS (author)2010-09-07

How about regulation: full power, power assist (like the ones on the e- bikes), slow speeds?

author
PickPacket (author)2010-09-07

Looks dangerous as hell, but excellent build!

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