How to Build a Battery Powered Bicycle
Electric-assist bicycles, or "e-bikes," are the fastest growing segment of the bike market in the Netherlands, where 30% of all trips are made by bicycle, according to a 2001 World Watch Institute report. They make it possible for beginning cyclists, older riders, and people who want to pull a heavy load, such as a trailer, to go farther, faster, and with less effort. You can buy a brand-new e-bike, but if you already own a bicycle, a conversion kit is a great way to re-cycle your cycle, while enjoying the benefits of the latest technology.
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Things You'll Need
- A bicycle
- E-bike conversion kit
- multi-bit screwdriver
- Allen keys
- Metric wrench set (or adjustable 'crescent' wrench)
- Pliers
Instructions
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Choose a conversion kit that will work for your bicycle and meet your needs. The most important thing to consider is how far you have to go and how fast you want to get there. The longer the distance the more battery power you will require. If your average trip has a lot of hills, you may want to consider the most powerful motor your local laws allow.
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Install the conversion kit. You will need to replace your current front or rear wheel (depending on the kit) with the one supplied with your conversion kit that has a "hub motor.' The choice of front or rear wheel hub motor is up to you, but typically people will choose a front hub motor if they are carrying the battery on their rear rack. If the battery is designed to fit on the frame of the bicycle, you can go with a front or rear hub motor. If you have front suspension on your bike, a rear hub motor is often the simplest solution as there can sometimes be issues with fitting the hub motor axle into the front shock drop outs.
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Attach the motor controller to the wiring harness as outlined in the instructions accompanying your conversion kit and clamp the controller onto your handlebars.
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Charge the battery and take your bike for a test ride. Stay within the manufacturer's claimed range until you have a better sense how far you can go before you run out of battery power. Hilly terrain, headwinds, and riding style (how much you use the electric assist) can all have significant impacts on the distance you can travel on a single charge.
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Tips & Warnings
Buy the best battery and most powerful motor you can afford. Lithium-ion batteries are the most popular choice for e-bikes, because they have the best power-to-weight ratio. Lead-acid batteries are the cheapest option, but they are heavy and bulky. Make sure your conversion kit complies with local regulations or you could get a ticket for driving an unlicensed motorbike. Make sure your brakes are in good working order. Your e-bike will accelerate faster and have a higher average speed than a regular bike.
E-bike conversion kits are designed to be easy for the average user to install, but as with all electrical projects, use the appropriate amount of caution and care when installing your kit. If you read the instructions and decide you don't know how to do it, find a local bike shop that can install the kit for you.
Because e-bike rules are different around the world, check with your area's motor vehicle regulations to ensure your choice of after-market kit doesn't exceed the maximum allowable power limits for an unlicensed, low-power motorized bicycle.
References
Resources
- Photo Credit bike sign image by Evan Meyer from Fotolia.com
