Wooden Electric Motorcycle

Introduction: Wooden Electric Motorcycle

About: After a degree in micro-engineering in Switzerland, I moved to Russia to discover new landscapes

After my electric wooden bike toy and my reproducible wooden bike, the next logical step was to build this wooden electric motorcycle. I found my local fablab a bunch of unused stuff that worked perfectly for this project: electrical motor, small lead acid batteries, speed regulator and wheelbarrow wheels.

Step 1: Tools and Material

Tools

  • CNC router (flexicam)
  • 3D printer
  • Hammer
  • Sandpaper
  • Press drill
  • 34mm drill bit
  • Hacksaw

Material

  • Plywood 18 mm (2m x 1m)
  • Lumber 40 x 20 mm (length:)
  • ABS filament
  • E-bike conversion kit
  • 2 lead acid batteries 12v 7Ah
  • Epoxy glue
  • White glue
  • M20 nuts and bolts
  • Cylindric lumber, diameter: 28mm length: 260mm (for curtain)

Step 2: Download the Parts

Download the dxf if you want to cut the parts directly. I also gave the solidworks files in case you want to modify something.

*Sorry I couldn't load zip and assembly files.

Step 3: Chassis Assembly

Clean the parts with sandpaper.

Now you can start assembling the chassis. (cf. image)

Be sure that everything works together before gluing. (white glue, wood glue or epoxy)

A big hammer can help but do not break the parts. If it is too difficult to assemble, go back to the sanding step.

Step 4: Fork Assembly

  • Drill the chassis
  • Pressfit the axle in the direction triangle (and glue)
  • Cut the direction triangle to ease the lumber passage
  • Insert the two lumbers 20 x 40 mm previously marked with the position
  • Secure the front wheel with the M20 bolt
  • Glue the down bearing on the triangle with epoxy
  • Glue the down bearing on the chassis
  • Glue the top bearing on the other side

Step 5: Drivetrain Assembly

  • Draw the part you need and print it (sorry I lost the file, it is just a cylinder with holes)
  • Tap the holes
  • Screw the sprocket on it
  • Screw the whole on the rear wheel
  • Place the rear wheel and the chain
  • secure the rear wheel with the wooden plates (last image)

Step 6: Add the Electric Parts

  • Secure the battery in place
  • Screw the motor on the wood
  • Secure the controller
  • Add the throttle (I adjusted the handlebar diameter)
  • Screw the handlebar
  • Secure the wires with zip ties

Try it! Stay safe! Add brakes!

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