The main stages for this project are:
- Setting your goals for distance and speed and creating a budget.
- Researching and ordering drive train parts.
- Testing the drive train
- Creating a model in SketchUp
- Obtaining and heat treating your bamboo.
- Hacking apart your donor bike
- Tacking the frame together
- Epoxy-ing the joints
- Creating mounts and attaching the drive train.
- Final parts and safety checks.
Screw driver (Phillips and flathead)
Computer w/ SketchUp
Batteries and charger
Bicycle breaks (front and rear)
Bike wheels and tires (front and rear)
Handlebars and stem
Two switches (one for controller killswitch, one battery circuit breaker Rear sprocket (match pitch with motor sprocket)
Chain (match pitch with motor sprocket)
Step 1: Setting Your Goals for Distance and Speed and Creating a Budget
For our project, we set the goals of a 25 mile cruising range and a 25 mph top speed. Because of some gearing complications we actually ended up with a top speed of around 35 mph.
Our budget ended up being around $1100, including one blown controller and a few tools we didn’t have already. Your budget will most likely be your limiting factor. It will determine the size and power density of your batteries (your most expensive part) and how powerful your motor is. It is important that you leave an extra couple hundred dollars in your budget for unexpected costs, because who wants motorcycle that almost runs?
Step 2: Researching and Ordering Drive Train Parts
Step 3: Testing the Drivetrain
Step 4: Creating a Model
Step 5: Obtaining and Heat Treating Your Bamboo
Step 6: Hacking Apart Your Donor Bike
Step 7: Tacking the Frame Together
Step 8: Epoxy the Joints
Step 9: Creating the Mounts and Mounting the Drive Train
Step 10: Wiring
Step 11: Final Parts and Safety Checks
Our seat was made by folding rags into the general shape we wanted, and then wrapping the rags with with duct tape. Still uncomfortable, but slightly less so.
As far as safety goes, we recommend a motorcycle helmet (a bike helmet at the very least) and that you probably should avoid riding this in the rain.