Scrap Gas Bike to Mean Green Geared Electric Commuter Bike

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Introduction: Scrap Gas Bike to Mean Green Geared Electric Commuter Bike

About: I like to build everything that works. Diy, how to, RC stuff, gadgets, reviews and everything about technology.

Hi

Guys, I am here with yet another interesting project on the electric motorcycle conversion or DIY project. I would clearly like to mention to you that this project is not for starters or fall under the home DIY category as it needs some specific tools and workshops to execute this. But it does not mean that you cant build one for you by getting some complicated jobs outsourced in a nearby workshop. This is a second iteration of the Bajaj Boxer, one of the popular bikes in the commuter segment in India made by Bajaj Auto. I got a very old and rusty scrap bike totally in nonworking condition. As you can see from the pictures above of before and after. The pictures of the old bike itself reveal the rusty and miserable shape it was in. This bike was totally worked upon and converted to a geared electric bike. This is the second bike that I have made. The first bike was a bit raw in shape and refinement.

I have kept the same concept of using the old bike's gearbox and converted it to a geared electric bike. I have used the original bike's gearbox but have replaced the original crankshaft with a customized one. I hope you guys will enjoy this Instructable

Step 1: Preparing Old Bike for Battery Tray and Electric Conversion

Old scrap bike gas tank was removed and a metal tray was fixed at its place. this will hold the new battery pack made with two parts of configuration 6s15p. The battery pack was split into two parts as the chassis pipe is passing in between the holding tray for the battery pack. You can also see the LifepO4 battery pack in two parts with all the balance wires taken out form the battery pack. The BMS was attached outside of the battery pack and the rest of the wiring from BMS and battery wires were connected. Finally, the XT90 connector was connected as a power output.

Step 2: Assembling the Electric Power Train With Old Gearbox

Above seen are some of the parts that were removed and are not required like silencer air filter original crankshaft magneto etc. Custom Gearbox is then assembled with a custom crankshaft that goes in as primary drive shaft and it goes inside to the gearbox. finally, the gearbox gives output at the trans axel which then drives the final wheel. No modifications were done in the final drive wheel sprocket.

Step 3: Installation of Gearbox and Motor on the Bike

Finally, the gearbox is installed on the bike chassis. L plate made of iron was then installed on the gearbox where the original block piston and valve head assembly was there. According to the requirement, the holes were made in the base of the L plate that will house the motor on a perpendicular face. You can have a look at the pictures above to get a better idea.

Step 4: Installation of Primary Drive Pulleys and Electronics

I have installed the pulley and belt drive as a primary drive system. This will drive the custom driveshaft going inside the gearbox which will drive the clutch and through trans axel, the power will be transmitted to the rear wheel. As seen in the above pictures the electronics like converter and motor controller were installed inside of the bike chassis where the air filter assembly was there. Also, you can see the charging socket installed on the gearbox side popping out. Also, you can see the battery packs mounted on the platform that was used to carry the battery pack in two halves.

Step 5: Display for Battery Capacity

I have used a simple digital display to show the battery voltage so that I can see how much charge is remaining. All the rest things like speedometer and light and horn switches are kept original. The display unit also houses the three-position switch that will offer three different power modes of the like economy, city, and sports. The three-position switch is wired to the controller.

Step 6: Custom Tank and Looks of Finished Bike From the Scrap

I made a custom tank that will cover the battery pack and made it waterproof as well. As you can see from the above pictures the completed bike. I have tried to give a modern retro look with some sort of futuristic design. I want to hear from you guys that how does the bike look like and what do you say about the color scheme in the e-bike.

Step 7: Performance

With a gearbox, this is bike can pull a lot of weight. As seen in picture I and my friend in doubles are easily climbing up the slope more than 35 degrees. You can also see the stills of the bike in motion. for further action,you can surely watch the entire video of the bike performance. I have been using this bike since I made it in August 2019 and not a single time the bike disappointed me.

The bike has decent pickup and power. It can travel a distance of 65 km per charge and I have given DC fast charging that can charge the bike from empty to full in just 2 hours flat. So what do you think of this bike? do let me know your thoughts in the comment section. thanks for reading it till the last.

I hope that you guys loved this instructable. Thanks once again...

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    26 Comments

    0
    LotsaHotsa
    LotsaHotsa

    Question 9 months ago on Introduction

    I'm interested in the cost of this motor. How do I get an answer?

    0
    shalbk
    shalbk

    Answer 5 months ago

    The entire project coated me about 900 USD. Sorry for so late reply

    1
    rjsde
    rjsde

    1 year ago on Step 7

    all gears work ? smart and amazing... but do electric bikes need gearbox actually ? what are the advantages of using the existing gear box ? do you find any difference in driving or battery life ? but I would say its really very interesting

    1
    shalbk
    shalbk

    Reply 1 year ago

    first of all thanks for your time and interest. Yes, all the gears of old petrol bike work the same way as it used to. Now regarding your second question that does electric bikes need gearbox the answer is yes and no both and I need to elaborate it as below
    electric motors due to their high starting torque may not need the gearbox but if you are using an adequately large motor with a lot of watts of power and in that too the motor needs to have the final reduction drive which increases the final wheel drive torque to provide that EV a traction capability under varying loads. Now scenario two is that we are using a lower power motor that does not produce the large torque which implies it does not have that large starting torque either. So for that reason, I have used the old bike gearbox as a four-speed torque converter which will provide traction to the vehicle under various load conditions and will manage to pull large loads owing to lower inherent torque curve of the motor. So I hope that I have answered your second question. Now the advantages of this system of using four gears are as below
    1) Can carry much higher loads than that the motor is alone capable of.
    2) This setup optimizes the usage of battery and strain on electronics plus large inrush of current can be avoided thus making the system lot strain-free and saving the valuable battery life.
    3) I am able to take advantage of using the smaller motor and than too able to achieve lot of load-carrying capacity even though the motor still remains in its efficient range.
    4) I can use the higher torque or higher speed depending on my need just like a conventional motorcycle which gives me very confident driving experience similar to what I am used to since years and than to I am not locked to using the clutch as there is no IC engine that will stall if the clutch is not pulled.
    5) Yes, I do feel a lot more like driving a conventional motorcycle rather than using a conventional EV with a fixed speed gear ratio in the final reduction drive. And it also helps in extending the battery life under varying loads.
    Once again thanks for your time and interest and I hope that I have answered all your queries.


    1
    NeilRG
    NeilRG

    Reply 1 year ago

    Your reasoning is brilliant and I agree with you. The high inrush current of a large motor requires larger everything else. I would believe that by not having a heavy battery pack high in the frame, that handing would be improved.

    0
    shalbk
    shalbk

    Reply 1 year ago

    Absolutely riding this bike is fun though not punchy acceleration but it's enough to beat most 100 cc two wheelers till 35 to 45 Kmph mark after that the person can overtake me but that's the most speed you can manage to have in congested Indian cities. Thanks for your time and interest ✌️👍😊🙏

    0
    madhavdivya
    madhavdivya

    Reply 1 year ago

    Great job. I appreciate it. Quick question: If the pulley on the gear box (the lower one) is larger, does it make a difference in performance?

    0
    shalbk
    shalbk

    Reply 1 year ago

    Thanks a million for appreciation. Yes if pulley on drive shaft is larger then you won't get much top speed and all what you get is tonne of torque it would be like tractor. No high speed but lot of traction and torque at wheel.

    2
    madhavdivya
    madhavdivya

    Reply 1 year ago

    Did you make the batteries yourself and how much did it cost you? What about the kit price? Any particular reason not to use a chain drive against your choice of belt drive? I would guess a chain drive lasts longer than a belt drive.

    Sorry more questions follow.

    0
    shalbk
    shalbk

    Reply 1 year ago

    Ya I have made battery pack my self I have all the stuff for making professional battery pack. It costed me around 36000/- INR entire conversion costed me around 65k including fast charger and old bike cost not included. I actually had chain drive in my first version instructable available for that as well. But I upgraded it to belt drive because it's much smoother and very less noisy than chain drive. Chain drive lasts longer but using belt drive I found to be more safe and I am not stressing drive belt too much as secondary transmission takes the most load to turn the rear wheel. Do worries feel free to ask me any questions you may have

    1
    mahesh_jo
    mahesh_jo

    1 year ago

    बहुत बढिया। शानदार और इनोवेटिव प्रोजेक्ट। एक अनुरोध है, भाई लोगों वीडियो के इंट्रो में जरा मुस्कुरा दिया करो यार। साथ में बाईक का बेकग्राउंड होता तो अच्छा रहता और उसे एक्सप्लेन करते जाते। बधाई।

    0
    shalbk
    shalbk

    Reply 1 year ago

    आपका बहुत-बहुत धन्यवाद और जो आपने बात कही मुस्कुराने की उसे हम जरूर ध्यान रखेंगे आगे से और भी वीडियो को इंटरेस्टिंग बनाने की कोशिश करेंगे

    1
    saitech01
    saitech01

    1 year ago

    superb engineering. .great masterpiece you have made. I really like the shape of battery cover tank that you have made it looks like teslas cyber truck but much better with your build. .

    0
    shalbk
    shalbk

    Reply 1 year ago

    Thanks a million for warm appreciation.

    0
    BOY MECHANIC
    BOY MECHANIC

    Question 1 year ago

    hi shalbk where did u get the motor?
    i.e. the link?
    I'm really interested in this motor cycle

    0
    shalbk
    shalbk

    Answer 1 year ago

    Hi
    Thanks for your keen interest. Motor is BLDC motor 1.2 KW erikshaw. And I have sourced it locally but if you are from India you will get times of those at dirt cheap rates in Delhi. It will cost you around 7 to 8 k for genuine one. Do let me know if you have any questions.

    0
    shalbk
    shalbk

    Reply 1 year ago

    Thanks a million

    0
    shalbk
    shalbk

    Reply 1 year ago

    Thanks a million bro...