How to build a 72Volt electric motorcycle

How to build a 72Volt electric motorcycle
No gas, no oil and almost silent. 72 Volts, 70mph of pure fun. This is how I built an electric motorcycle.
 
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Step 1Why and how

Why and how
I only work 3 miles from home but with gas prices getting out of control, I thought it would be great to have an electric vehicle. I've always wanted a motorcycle and decided that making an electric motorcycle would be a good EV project, keeping costs down, and be fun to ride.

This project took about 3 months of research and development (not counting waiting for parts to come in or help from a friend with the welding). All in all, it cost about $3000 to buy and build. This may take a long time to pay off in gas savings, but if you add the fun of building and all of the environmental benefits, it was well worth the effort. With a top speed of over 70 mph and 10 miles per charge, this vehicle is perfect for me. The following instructable will not give you exact step by step instructions, but if you have some mechanical skills and welding ability you should be okay. A little knowledge of motorcycle maintenance wouldn't hurt, too. However, I just read the user's manual and learned as I went.
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543 comments
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Feb 13, 2010. 1:06 AMgggiiilllbbbeeerrrttt says:
where do you find an old motorcyle

Feb 17, 2010. 7:49 AMKarletto555 says:
in a junkyard
Feb 5, 2012. 9:44 PMrainbowrider42 says:
Hello Stryker. This is my second post here since I became an avid follower of all the instructable projects in this site for five years already. I admire your e-bike project. Can I request for the pdf of your instructable coz i can't download it here for no apparent reason. Maybe something wrong with my pc. My email add: laurel_mj@yahoo.com. I want to make my own e-bike based on your design. I'm from the Philippines and the cost of gas here is very high for my motorcycle. Thanks to this site, I receive an email regarding the projects of e-bikes and I really like to make my own to cut down the cost of riding my motorcycle. Thanks a lot.
Feb 5, 2012. 9:33 PMrainbowrider42 says:
Hi, This is my first interaction here in Instructables though i've been browsing and reading comments on every project for more that 5 years. First: I really like your project that I wanted to make my own. I really admire your E-bike finished product. Secondly, Is it ok for you if I request you to send me the instructions via e-mail coz i can't download the pdf of your instructable here? you may send it to: laurel_mj@yahoo.com. thanks a lot. If I receive your email, immediately i will start making my own e-bike based on your concept. BTW, I am from the Philippines and I love this site and all the projects here. KUDOS to everybody who shared their talents, time, efforts. I salute to the people behind this site.
Oct 23, 2011. 5:25 PMearthwindwater says:
That is a very slick conversion! Nice!
Sep 19, 2011. 6:38 PMsteveo625c6 says:
What are some of the specs:

How many HP is the motor?

Top speed?

Sep 19, 2011. 12:01 PMkenbob says:
Beautiful work
Aug 20, 2011. 6:08 PMpubicperm says:
Okay as for the people commenting about the perpetual motion. Why can we not build something that uses multiple forms of recharging, re-generative brakes magnetos on the wheels, an air inlet with a turbine and maybe some solar paneling too? In motorcycle format this doesn't seem impossible because their is a lot less drag and resistance.
Aug 27, 2011. 2:00 AMandrew.downs1990 says:
Any machanical work needed to generate electrical energy requires it's own energy source to drive it, and this energy is always greater than the electrical energy produced.

The Second Law of thermodynamics essentially says that energy exhibits entropy. It moves away form its source. In machine terms, you have to add energy to get more work, and the ratio of energy to work will never equal 100% due to energy expanding away from its source.

Solar pannels are a good source of energy used to get work but all other forms of "self recharging" through a mechanical means would require work and energy of a greater amount that it would produce.
Sep 19, 2011. 8:22 AMdans060887 says:
This is all true. But by adding magnetos, or re-gen brakes could lessen the strain on the batteries causing them to stay charged longer and therefore increase the range of the vehicle.
Aug 31, 2011. 12:41 AMtootall1121 says:
Some of today's vehicles have the charging feature from the wheels during braking. Not a big deal to think up, somebody in my sixth grade class thought of it way back in the dark ages. Harder to do, though. I truly think that electric is not the way to go for vehicles, until and unless very high capacity batteries become widely available. Alternative fuels, turbine engines, or maybe even a new version of a Wankle, seem more likely. It's possible to run a standard internal combustion engine on anything that burns. the better it burns the better fuel it is, but I've seen a pickup truck powered this way, the owner preferred wood chips and sawdust. Basically the material is contained in a "smoker" that heats the material, but oxygen is at a minimum, so it doesn't burn with a flame, it just smokes. heat has to initially come from some source like alcohol, to get it started, but once smoking is no longer required. Another way to handle that would be to start the engine on another fuel, say propane, then once the exhaust gets hot, let it heat the material. The engine burns the smoke via a carburetor, in this case one designed for propane originally. I can envision this gas being compressed by what amounts to a supercharger, mixed with compressed air, to make an efficient, high performance engine. The original wasn't but that doesn't mean it couldn't be done that way. Oh by the way, an auger system keeps fuel in the "smoker."
Aug 11, 2011. 9:11 AMeraj1 says:
hello sir,
Is there any possible of regenerating in E-bike.
Aug 10, 2011. 7:41 AMtim127 says:
thats really cool, i wouldnt even know it was home built. how many volts is one of those battaries and how much did they cost?
Jan 5, 2011. 10:16 PMkrashtest says:
Couldn't you charge the batteries while riding with a magneto? Lotsa volts with a minimal drag. They got the old brit bikes down the road for years, and todays electronics technology being what it is......just wonderin.
Jan 9, 2011. 1:04 PMluckadoo42 says:
Wouldnt that be perpetual motion, though?
Feb 13, 2011. 11:47 PMkrashtest says:
Not perpetual motion. Anybody got any unobtanium? I'm just wonderin why the hybrids are only charging on regenerative braking or whatnot. Magnetos produce thousands of volts,(when working right), and require very minimal energy to operate. Not trying to sound like a downer, but I can't help thinking that so many of the hurdles we now face, in respect to fossil fuel free transportation, will quickly disappear as soon as chevron or bp put their business models in place to maximize their profits from the industry. The LAST thing the corporate giants want right now is fossil free futures. Drill baby drill! Alas....I rant.
Feb 14, 2011. 5:06 PMluckadoo42 says:
Just out of curiosity, do they call unobtanium because its unobtainable or does it have some sort of latin meaning?
Aug 1, 2011. 6:03 AMStuNutt says:
I think that "unobtanium" may be a "Terry-Pratchett-ism" to me.
Feb 14, 2011. 11:03 PMkrashtest says:
Its as obtainable as upsadaisium....Hey Rocky! Watch me pull a hat outta my rabbit! I'm just sayin luck, I kinda think we've been saddled with a bad bill of goods. This is corporate america. We certainly need more Teslas around. I hear they're doin some cool stuff with capacitors now instead of or maybe in conjunction with batteries.
Jan 26, 2011. 10:18 AMbadideasrus says:
well, technically no. the magneto will never make as much energy as you use. but it should boost.... time between charges?(man, i only speak English and i can't figure out how to say it..... why is our language so dang hard?)
Jan 28, 2011. 4:30 PMluckadoo42 says:
Ah, yes, but it takes energy to change energy from one form to the other, and in the process, one almost always losses energy (if you didn't, then that would be 100% efficiency...), so any increase in time between charges would be minimal, which means that any energy gained would probably be countered by something else that just dislike perfection.
Feb 11, 2011. 1:10 PMbadideasrus says:
i see your point, though i didn't quite get that last bit.

but still, we both agree it's not going to create perpetual motion.

magnetos work so well with 'those old dirt bikes' because a gas engine creates tons of energy, much more than needed to get you down the road.

off course, you could always peddal :) lol
Mar 13, 2011. 7:18 AMmcmonte says:
I wanted to do something like this 14 years ago. Then about 8 years ago, 4 years ago and now I'm over it. Every time I want a bike I read something in the paper, or see something on the news that stops me cold. I digress,

If you want to increase range a little more, additional methods include:
- use a brushless motor
- get the best batteries you can. Absorbed glass mat (AGM) aren't quite the pinnacle, but they can't leak and some have good capacities
- consider small, flexible solar panels that can conform to top-facing surfaces like top of fuel tank, ducktail etc. Trickle-charge a little while parked!
- consider these little buggers: http://www.dealextreme.com/p/wind-powered-led-light-for-vehicles-2-pack-5172

Might seem silly, but my idea was to place these tiny wind generators in fairing gaps (where airflow to voltage controller etc would not be affected).
So maybe 6 or 8 of these little guys, (of course you removed the leds) to divert the energy produced into an auxiliary channel of the charging circuit.
It could work!
Apr 11, 2011. 7:46 AMdoodle moo says:
if you added wsmall wind turbines it would make it slightly harder to drive meaning it would use more electricity so much so that you would not gain any and would loose a little bit
Apr 11, 2011. 7:02 PMmcmonte says:
I agree if they were wind turbines in the common, huge sense.
...but click the link provided ^

These are tiny, lightweight plastic items that represent NO parasitic loss. They're designed for bicycle or car exterior and as they spin, generate something like 1V (if that) to illuminate one LED.

If the air is passing through a vent anyway, why not use it?
May 6, 2011. 12:26 PMjmengel says:
If the tiny, lightweight plastic items truly represented no parasitic loss then they would not light the LED. The reason not to use the air passing through the vent anyway is called thermodynamics, as in there is no free lunch.
May 6, 2011. 7:25 PMmcmonte says:
Ahh, so the blade that weighs 0.1 gram spinning in an otherwise wasted air channel is not worth doing. I see.

By themselves, the little wind powered LEDs *do* have a degree of inefficiency, as they don't use high quality bearings etc. Yes, there is some friction.

In the context of the overall project though, you're getting a bit of electricity for what? Negligible wind resistance.

Using your argument, you'd also oppose the use of a capacitor to store static electricity from the riders body. Well, the cap *weighs* something doesn't it? lol
May 21, 2011. 2:59 PMAndsetinn says:
Let´s just say that if wind turbines are not powerful enough to cause losses they are not powerful enough to drive the motorcycle.

Solar cells small enough to not effect the shape of the vehicle are not powerful enough to drive it.

Because of losses in each step of transformation, of wind energy to electric energy to chemical energy (battery) to electric energy to moving energy again, and losses in storage. It is clear that no equipment attached to moving vehicle, and driven by it´s movement, will ever cause it to go faster or further. If it could, we'd have solved humankind's energy problems.
May 22, 2011. 12:09 AMzack247 says:
i think mcmonte was saying to use the little turbines to trickle charge the batteries, but in my opinion, i would use them to charge a small 7.2v battery and run all of the lights off of that, im sure that would save energy, wouldnt it?
May 22, 2011. 6:12 AMmcmonte says:
@Andsetinn: I never suggested using an array of tiny generators to "drive the motorcycle". I'm not so naive to seriously believe that is possible. My original suggestion was merely to help *offset* the discharge. Remember, the batteries used for these projects aren't huge capacity, because the higher the capacity of the battery, the more it weighs.
Trickle-charge - anybody heard of that concept?

@zack247: Yes, ancillaries circuit or trickle back into the speed controller, maybe take 1-2% load off the main batteries. Or how about a super-capacitor? Why not charge that for an extra speed burst?

About 5 years ago, a South African solar company launched a new type of solar film. Supposedly, it could conform to almost any shape. Why not use something like that on a vehicle? Some electric/hybrid concept cars have solar panels on the roof.

Those little solar powered window-mount ventilator fans have been around 10+ years and they seem to work.

Personally, I'd be happy to park my vehicle outside during the day to help *offset* the discharge from my morning commute. Even if it means 1 hour less recharging at home, that's money saved, is it not?
Jul 3, 2011. 9:57 PMemanpa68 says:
If cost is your concern, the payback on the solar setup would take a very long time, plus during the installation you would need to offset the additional weight to make it payback faster.


Anyways, about the wind turbines, these types of "troll physics" drives my ocd crazy. Not to sound like an attack, but honestly the net result will be negative installing that product.

Even if your goal is to ease the use of your batteries, that will be impossible to achieve. The total drag and added weight (however minuscule) will never be more efficient then direct wiring to the battery (solar setup in a 0 drag manner and performing a weight reduction of the bike would though!). The batteries will have to work harder to get you to where you want to go (even a tiny bit harder still counts as work)

Conservation of energy will always cause on board wind systems to fail.
Jul 4, 2011. 1:35 AMmcmonte says:
Oh, and if weight saving is so important to you, why not remove the rider from the equation?

After all, the human form needs a fairing help reduce drag. The fairing weighs something. So do away with both.
Win-win.
Jul 4, 2011. 8:19 AMemanpa68 says:
What? I hope that was a joke, lol... yeah, taking a s**t would probably offset the weight and drag of those wind power lights so yeah... that would work...
Jul 4, 2011. 1:33 AMmcmonte says:
No, cost is not my concern. In fact, nothing is of concern to me at all.

As my first comment alluded, I grew out of motorcycles over 20 years ago. I have no desire to reprise that chapter of my life.

What I offered are suggestions. They need not be taken literally. They might get some people thinking "outside the box" and I reckon that can only be a good thing.

After all, it's through experimentation, and often quite by accident, that new things are discovered or invented.
May 30, 2011. 6:23 PMAndsetinn says:
Sorry for that. When I said/wrote "not powerful enough to drive the motorcycle.". I meant to say assist in driving the motorcycle. But that is not right either. They can assist in driving the motorcycle.

The thing is, as I pointed out in the last paragraph, that because of losses in energy conversions wind turbines will cause more drag than the power they create to "assist in driving the motorcycle" so the net effect would be that they'd slow the motorcycle down.

Solar cells need to be about 10 cm on each side to make 1 watt each hour. (like these super solar cells at amazon http://www.amazon.com/Super-Solar-Cells-0-5V-2-pk/dp/B002MAYDZ4). Each battery can store almost 500 watt-hours (when new), and there are six of them making the total almost 3000 watt-hours. The motorcycle goes 10 miles per charge, 300 watt-hours per mile (which is low if you ask me, because 1 horsepower is calculated as over 700 watts and you certainly need more than 1 horsepower to reach 70 mph). If you have very sunny days and daylight for 16 hours each day it would take almost 190 days to fully charge the batteries using 4 of the cells from amazon. Or for 8 hour charge (a working day) you could drive the motorcycle for 130 feet, about the length of a 1 and a half basketball courts.
May 23, 2011. 6:54 AMjmengel says:
Why not just skip right to making a perpetual motion machine?
May 23, 2011. 5:37 PMmcmonte says:
lol you have 16 'ibles under your belt, so I'll defer to your obvious level of mastery in all things creative. Might I suggest longitudinal electromagnetism? You know, what Nicola Tesla invented about 100 years ago?

As to your comprehension of the English written word? Sorry.
Perhaps you should look up definitions of the words "offset" and "recovery" because in part, that's what my original post suggested.
Sep 19, 2011. 12:12 PMrashidmaroof says:
hey guys did you see this video of the "forever electric car" it goes along your topic of windturbine used in a vehicle, very cool concept. i think it should be used somehow to "offset" (lol) fuel consumption.

please click link, you will love it. i did

http://www.youtube.com/watch?v=bkcn8ZkvKKc&feature=results_main&playnext=1&list=PL5F22FE96F32E4208
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Author:Stryker