Instructables

Poor Man's Electric bike made by Recycled materials from Junkyards.

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Background:
I am Naeem Zahid, aging 39 from Pakistan (City Peshawar). It was in me since my childhood when I sued to break my toys and make something else from them. I have no professional qualification in engineering or electronics but I have learned everything from books and mostly the Internet and from local mechanics. It took me years to learn electronics, welding, and electric motor winding. Every step I took to make this was a first time. Some time I wonder that how did I do it? But it was the desperate desire to do something good to the humanity, to at-least play my role for the betterment of green planet earth, I made my electric bike from parts collected from different junkyards in my City "Peshawar" which is a hot zone from few years and has been targeted by terrorists, while I have been doing my best to make a way to set an examples for the others and giving them the message to do good in the name of God and you keep doing it no matter how much wind is against you. I am a man of very low income, therefore, there was a situation of stop and start in my case of project. It took me about 10 years to make this for the reasons I mentioned earlier and for the fact that I had to learn to do what ever I wanted to do it takes time. Suppose I needed to learn welding: I learned it from a local welder on weekly basis lesson on payment. I had to rewind a DC brushed type motor so I learned rewinding from a mechanic He was kind enough to teach me for free, so on and so forth.
In 2008 I got the chance to take part in a science competition where the competitors were Doctors and Engineers with their superb creations My “Very low cost electric bike” won 2nd position with an award, a shield, a certificate and cash prize of Rs. 8,000 (about USD $ 93). Again In 2009 the Secretary of Science and Information Technology gave me a certificate of honour and a souvenir.

Materials:
I have used pipes from junkyards to make the frame which I drew on paper. I had no welding equipment at that time so I used to go to Shoba Bazar, a place which I used to call as heaven for so many mechanic shops in one place.
I have been using different motors for my electric bike but the best I have found was a motor I found in a junkyard is mostly found in the Car’s fan for heat radiator of engine. It had more room on rotor to accommodate more wire.
Only the batteries (SLAs) are new which I bought by the money I collected in years. And for this my project stood still for a long time. It is truly very painful at times when you have no money to go on.
About the controller:
In the beginning it was running on 12 Volts, just stop and start with higher gearing ratio and a speed not more than 17 – 20 km/hr. After increasing the number of winds I went for higher voltage and greater torque I had to have some sort of speed controller. I came to know about electronic speed controllers for dc motors and started educating my self on internet about electronics basics. At last I found a controller diagram and set out for parts. Again short of budget and wait till I get rich enough to buy parts. Bought the parts made the controller and a Failed all parts destroyed. While lost in tears I thought I would give up but I didn’t, instead I kept thinking a way around. And came up with a strategy to use High amp relays used in cars to controller heaters and other high amp stuffs. I made a home made switch which was controlled with a thumb throttle and switched the batteries (5 of them each 6 volt 10 amps) to parallel and series in 4 stages (12, 18, 24 and 30 volts). It worked like a magic and I kept it for 2 years. I started using my bike as my means to travel to office and back which is 13 km away from my home. My bike was a moped so at the end of my ride I had to paddle for little juice in batteries.
After knowing the efficiency of an electronic controller I once again started my search for a diagram containing less expensive components. The Main expensive thing among the components were the MOSFETs. I found one (IRFP150n) very cheap and modified a diagram to work with these MOSFETs and it worked very well. Since then I have this controller which is now well modified and working without any problem till today.

Gearing:
While climbing a steep hill I had this option to switch the gears to a higher ratio which puts lesser lode on motor although the speed drops down but it puts lesser strain on batteries and motor and also increases motor and battery life as well.

Updates:
Right now I have converted my bike design to a Recumbent (high racer) with a wide range variable transmission system and a homemade front suspension that works extraordinarily. In the toughest off-road situation it feels like I am in a boat, on water, not on a bike and it gives me such an amazing feeling of happiness which can’t be explained in words. With 5 SLAs and the same controller and a recumbent design top speed is about 55 – 60 km/hr on straight while climbing a 40 degree hill speed is about 40 km/hr. I have gone about 30 km but still there was juice in the batteries so I can safely say 30 – 35 km per charge. I live in a very small city and my office is at the other end of the city which is about 13.4 km away.
It is the first of its kind in my city, so people gather around me on bikes and cars during my ride to office and take pictures of me and make videos. I can’t go to shopping on this as this creates a crowd which creates traffic jam situation therefore I am prohibited to bring this inside city market for shopping by the police and authorities. I am sure that I have laid down the foundation of Electric Vehicles in my part of the world. It is my effort towards saving planet earth. Please, join hands with me and do good in the name of God not for Muslims, not for Christians not for Jews, but for human race, regardless of any geographical boundaries, cast or creed. May Allah Bless you all.
Respectfully Yours
Naeem


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Vishnu I P2 months ago

Hai....

I have a 24v dc ,80 watt DC motor .... will Ibe able to make a electric cycle with that?

Anticipating for your replay

jharley3 months ago

Hi Naeem,

What an awesome and amazing electric bike. I'm just starting my e-bike project (in planning phase), and I came across this page. I really enjoyed reading your description of the process. It really took you 10 years to build?? To dedicate that much time to a project(any project) is very admirable. Amazing dedication.

The design of your controller is a great idea, and was done very well. That combined with the transmission system is really a work of art. The rewinding of the motor is a great idea as well, and I think I'll put it to use on my project to save a couple hundred dollars on a motor. I can use that money for something else, like paint, and fixing up my bikes tires/chain.

What I really like about your project is that you've show people that it's possible to build a bike from scrap within your country(area of the world), and if you can teach other people where you live how to do it, then you can help change the world one e-bike at a time. Of course, any bicycle is green (as in no toxic waste from the "tailpipe"), however, you are achieving motorized green transportation with locally sourced parts. That is how movements are started. I really hope you are promoting or teaching this to as many people as you can. The greenhouse gasses from vehicles in countries all over the world is causing havoc on the climate. If enough people made the switch to electric then possible the trends can start to change. Seeing this bike gives me hope.

Reading your instructable has inspired me to try and recycle as many parts as I can from thrift stores, and old devices that people throw away. I'll create an instructable on my project as well in case you're interested in seeing what you helped inspire and maybe I can inspire someone else.

Best regards,

James
WNY New York

fanatic7774 months ago

jiyo Pakistaaaaaan.....

fanatic7774 months ago

jiyo Pakistaaaaaan.....

gud work
echoalex10 months ago
Extreme awesomeness !! All the best..
Advar11 months ago
You, Sir, are an insperation not only to me, but I dare say anybody that needs, wants and has to do something themselves, either by choice or nessesity. Thank you very much for showing us this great project. :)
sgl71 year ago
Congratulations for the strength of constancy and perseverance ......GREAT JOB...!!!
i like your bike great job
lumpsucker1 year ago
God bless you brother. More power to your elbow.
great job
Love it keep your head up
drsamuelk2 years ago
Magnificient Mr. Naeem.
Greetings from a neighbour. I can understand your initial frustrations, it's the same here in India. Whenever we ask around for EV parts, the first question is 'Why do want to do this silly project, aren't gasoline bikes more powerful and efficient?' I rallied around for a motor but couldn't find one powerful enough. The "Agni - Lynch DC motor" is made in Gujarat, India but a price tag of $1100 USD put me off. I make just that money in a month but my family won't look at me sympathetically. I'm now collecting info on making motors. I got interested in LRK brushless outrunning motors. I haven't seen many used on motorcycles. The problem is even magnets are hard to get by, in India. What I like about your project is the electronic controller you made yourself. Would you care to put up the link of the circuit online. I hope you start a firm manufacturing motors and controllers and get rich.
Why dont you use 2 of those electric scooty motors?
I am eager to help you, i live in delhi , please tell me how can i help you!
numberonebikeslover (author)  qwerty1561 year ago
Oh great idea but the thing known as e-moter is next to impossible to find here in my city. I modified a radiator fan motor to achieve my goal. Thanks for the comment.
numberonebikeslover (author)  drsamuelk1 year ago
I am really sorry for being so late in responding to your comment. My brother I always say that when you are in search of some thing in the world, God will show you the path only if your heart truly wants it. Please see my thread in making all the controller and everything. If you could find it useful even a bit it would be great honour for me. please go through pages and you will find the required information and may be more. I am in a situation like yours so you might find more in DIY (do it your self) stuff. here is the link: http://endless-sphere.com/forums/viewtopic.php?f=6&t=3983&start=330
I hope the website would allow this link to be published with this comment.
upevnz1 year ago
Great Work keep it up Naeem!
gene3282 years ago
This is really good. I don't see how I could ever give up now on my project.
Having not much to work with its sometimes hard to keep going.
Thanks for shairing your story with us. It gives me the Energy to keep going.
Gene in Washington State, USA
qwerty1562 years ago
Very good job sir!
I admire your determination and perseverance!

I am sure many Indians and Pakistanis will be inspired by your good work!
qwerty1562 years ago
Very good job sir!
I admire your determination and perseverance!

I am sure many Indians and Pakistanis will be inspired by your good work!
prusty_anil2 years ago
very good project :)
Outstanding!
cnludwig3 years ago
I really like your bike. I like the fact that you used otherwise discarded materials. I would love to see a video of you riding it!!
numberonebikeslover (author)  cnludwig2 years ago
Cnludwing; I am sorry for a delayed response. try and search this string "Pakistani Electric Bike" on youtube you will find my video(s) I have the same ID/Nick i.e. "numberonebikeslover" in youtube as well. Subscribe to my channel and you can see all my videos and my further work in progress on different things.
Thanks Naeem! I love the video. Thanks.
shad0w883 years ago
Proud to have a fellow Pakistani accomplish something like this, while all others use motors and parts which are bought. You have made even the motor yourself!! Awesome work!
numberonebikeslover (author)  shad0w882 years ago
My father says that do good to humanity in the name of God and never ask for favours in return and you will always be blessed. So take it as a one man's effort towards making earth a green planet.
nigel cox2 years ago
Congratulations Naeem, this is a true case of determination against the odds, you have shown people what can be achieved with a minimum of materials avaliable, this shows how easy we have it here, it is worth trying to get hold of old sealed batteries that are being scrapped, take the tops off and refill them with distilled water just up to the top of the plates and recharge them, many times these will come back to life and if they don,t have a look at battery desulphaters in instructables and have a go at building one, if you can,t get or afford the parts let me know and I will send you them at no cost to help you carry on recycling for the earth, keep on inspiring people, full regards Doc Cox
isamuel2 years ago
nice work! u must ave suffered very hard 2 gt 2 finish this?
msubzwari3 years ago
This is excellent. Great job Naeem.

+1 to above comment by @I8nite.

Consider your readers here that how can they build such a bike step-by-step and update the instructable accordingly. You have a fabulous DIY product, if you make the instructions easy for others to follow, it will be a great instructable as well.

I am feeling very proud having a fellow Pakistani put up such a nice DIY design.
numberonebikeslover (author)  msubzwari3 years ago
Well; due to my official engagements, I don't find enough time to pursue such activity. Any way I have my detailed story in Endless-sphere.com website in the following link:
http://endless-sphere.com/forums/viewtopic.php?f=6&t=3983&start=0

Page 1 - 16 If you follow every page I am sure it will enable many people to make such a thing.
Thanks for the comment.
Naem
really the best electric bike of this forum man!!

Thanks, inspiring bike, inspiring attitude!!


Roberto Neumann

Mexico
chadmanmn3 years ago
Hi Naeem,

I was looking at electric bikes and your instructionable popped up in the "related" sidebar. I have to be honest when I say that I clicked on your story it was because I thought your bike was so ugly. However, after reading your story, I view your bike as a thing of beauty.

Keep on working and learning, and I hope that someday you are able to turn your passion and knowledge into a successful business to help others in your region.

Best of luck,
Chad
Minnesota, USA
bahi3 years ago
Awesome! Do you have any vids?
l8nite3 years ago
looks great ! more and better pictures would help
numberonebikeslover (author)  l8nite3 years ago
I had many more, it is just that a virus destroyed my computer few years back. I am sorry these are all I had. Follow my work on Endless-sphere.com if you want to know that details.
Naeem
Kwakpiper3 years ago
+1 @l8nite

Great job Naeem !

numberonebikeslover (author)  Kwakpiper3 years ago
Thanks man.
Great Work!! Happy to see a Pakistani doing stuff like this
iPodGuy3 years ago
Nice!
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