How To Build An Electric Motorcycle Ep 1: Chassis & Suspension
Вставка
- Опубліковано 19 вер 2020
- How To Build An Electric Motorcycle. Get the plans: renewablesystemstechnology.co...
In this video I build the chassis for a new electric streetfighter motorcycle. As some of you know, I've been planning and working on the design for most of the year. I took inspiration for some of the cosmetic elements from a few other bikes like the Magpul Ronin (a Beull 1125) and the KTM Duke, as well as my previous motorbike project.
The chassis is all steel. Yes, I know. Again. My flux core MIG limits me to working with steel because no one makes flux core aluminum MIG wire - some people sell it on Ebay and Amazon, but it's actually solid wire that requires gas. I do plan to upgrade to a more powerful arc welder in the near future so that I can use aluminum for projects like this. But for now the extra 15-20 lbs isn't going to make much of a difference, especially since this bikes total weight will still be 100 lbs less than a conventional bike in its class.
As you can guess from the title, I'll be uploading a series of videos for the build as it progresses, this being the first with two more to follow in an effort to establish a more regular uploading schedule for you folks. This week I'll be making the foam plug and sock and mother molds, then use them to cast the fairing components. Keep an eye out for that video in the next week or two. The final video will be the complete build from start to finish, with a short test drive at the end. As always, a complete set of plans with a material list will be available when the build is finished. Links for suppliers of the components featured in this video are below.
Get the plans for this project here: renewablesystemstechnology.co...
Specifications:
Power: 12 kw/ 24 kWp, 32 hp
Motor: QS273 70H brushless hub motor
Battery: 74V/4.3 kWh Li-Po
Range: up to 100 km's
Controller: Kelly KLS72601
Wheelbase: 55" (140 cm)
Rake angle: 26°
Trail: 4.9" (124.5 mm)
Turning radius: 72" (183 cm)
Weight: 300 lb (136 kg)
Front suspension travel: 5" (130 mm)
Rear suspension travel: 8" (203 mm)
Front tire: 120/70-17 Shinko 705
Rear tire: 180/55-17 Metzler Karoo Street
Steel tubing:
www.metalsdepot.com/category/...
Hub motor:
www.qsmotor.com/product/17-in...
Rear suspension:
www.ebay.com/itm/250mm-10-Rea...
Front suspension:
www.ebay.com/sch/i.html?_from...
Front tire:
fortnine.ca/en/shinko-705-ser...
Rear tire:
fortnine.ca/en/metzeler-karoo...
Front wheel:
www.ebay.com/itm/17-x3-5-Allo...
Clip on handlebars:
www.ebay.com/itm/50mm-7-8-Tub...
Self lubricating bronze bushings:
www.fastenal.com/products/det...
The tool guide used to cut the bearing races in the video:
• How To Build The Modul...
Don't like ads? Neither do I. I hate them. That's why I signed up for a premium UA-cam account for $12/month so that I never have to see another ad on this site again, and feel good knowing that I'm contributing to the creators I like so that they keep posting more great content. I highly recommend it. If you're just here to watch my videos, that's cool too. You can help support me specifically by signing up for a channel membership instead. Then just keep an eye on the community tab to watch these videos free of advertisements. You'll also get other perks, too. Check out the links below if you're interested.
UA-cam premium account:
ua-cam.com/users/premium?ybp=S...
Support RST specifically:
/ resystech
/ @jamesbiggar
Follow RST on Facebook:
/ renewablesystemstechno... - Навчання та стиль
Get the plans for this project here: renewablesystemstechnology.com/electric-streetfighter.html
this dude builds THE DOPEST stuff with the simplest tools. *respect*
Some company should sponsor this guys with a quality TIG. It would take his work to the next level. Loving the build as always. I am looking forward to the next chapter!.
Even without having seen the final product, I can tell this thing should be mass produced. Awesome work!
@ mario - would not be a good idea, because the manufacturer will start cinching on material
stating that it is good for the company to survive .
You're a god amongst men in the electric mobility community
Thanks for providing this material, James. It is much appreciated.
I love that you aren't using fancy tools to make this incredible bike. Instead, you are just a wicked smart dude who can figure out how to make wicked awesome stuff with what you've got!
My mind got blown away the way you made the head tube bearing race🤯🤯
I think most amazing thing about him is how he is building everything with simple accessible tools...don't get me wrong Pro tools are obviously good and makes life easier but those are expensive and mostly not accessible to hobbyist.Hardly saw any youtuber who actually does this level of high quality DIY builds.
Great build, thank you for being a creator and sharing your builds with us.
That looks awesome. Looking forward to the next video
Thank you for sharing. Very wonderful work.
Looks dope and interesting. Can't wait for the next part!
Love your work men ! Can't wait for the next part thank you ;) !
Amazing project, massive respect for your fabrication skills.
That's cool! Waiting for the next video
Love and respect your hard work man
EPIC !!! That looks Amazing !!!
I’m so excited for part 2
Very impressive metalwork, I've never seen someone make such complicated parts out of straight tubing with basic hand tools.
Is the CAD file available for download?
Much respect sir. Amazing inspiration.
Great stuff James!
You're grat! It's been my dream for long time to build a motorcycle. I hope i can learn something watching your build. Thank you for posting these videos!!. Wait for the next xD
Amazing stuff! Just like the last bike... 👍
what a craft man ship i Love ur work
Super job. J'attends la fin du projet. Impressionnant. Félicitations de France.
i swear the way you cut the metal pieces are just absolutely godlike dude. fucking awesome stuff!
Mate you are a wizard, you don’t need tools you could do the same with paperclips and elastic bands.Awesome build
always love ur builds,awesome work sir
Definitivamente o melhor video que ja vi no youtube... Parabens - Ganhou um escrito...
I've been getting quite a few comments regarding the bronze bushings that I used for the swingarm pivot bar and why I didn't install a bearing kit instead. The answer is very simple - because bronze bushings are very rugged contrary to popular belief, and a lot more affordable than bearings. They're commonly used in low speed, high load/severe-duty industrial applications for this reason. These bushings in particular are from Fastenal. They're rated for 2000 lb/f of dynamic load and are self lubricating, meaning they're impregnated with oil so that as the bushing wears SLOWLY over time just as a bearing does, oil is gradually released to keep things lubricated so no grease nipples are required. A swingarm pivot bar is the perfect application for an appropriately sized bronze bushing. So why do most manufacturers use bearings instead? Another simple answer. The more replacement parts cost, the more $ the manufacturer is going to make from you after they sell you a bike. Specifications:
Power: 12 kw/ 24 kWp, 32 hp
Motor: QS273 70H brushless hub motor
Battery: 72V/4.3 kWh Li-Po
Range: up to 100 km's
Controller: Kelly KLS72601
Wheelbase: 55" (140 cm)
Rake angle: 26°
Turning radius: 72" (183 cm)
Weight: 250 lb (114 kg)
Front suspension travel: 5" (130 mm)
Rear suspension travel: 8" (203 mm)
Front tire: 120/70-17 Shinko 705
Rear tire: 180/55-17 Metzler Karoo Street
Steel tubing:
www.metalsdepot.com/category/steel-products
Hub motor:
www.qsmotor.com/product/17-inch-12kw-hub-motor/
Rear suspension:
www.ebay.com/itm/250mm-10-Rear-Shock-Suspension-for-SSR-SDG-Pit-Dirt-Bike-Project-980LBS/113714113355?
Front suspension:
www.ebay.com/sch/i.html?_from=R40&_trksid=p2057872.m570.l1313&_nkw=2002+suzuki+gsxr+750+front+suspension&_sacat=0
Front tire:
fortnine.ca/en/shinko-705-series-dual-sport-front-tire
Rear tire:
fortnine.ca/en/metzeler-karoo-street-rear-tire
Front wheel:
www.ebay.com/itm/17-x3-5-Alloy-Front-Wheel-Rim-for-Suzuki-GSXR750-92-95-GSF-1200-Bandit-97-05/143627872008?
Clip on handlebars:
www.ebay.com/itm/50mm-7-8-Tube-CNC-Motorcycle-Universal-Clip-On-Ons-Fork-Handle-Bar-Handlebars/182681550392?
Self lubricating bronze bushings:
www.fastenal.com/products/details/0435438;jsessionid=HC1deNskq4Q1FdJ6HYJ8jYYL.443d7b2e-1555-3602-a586-c0d73327934b
The tool guide used to cut the bearing races in the video:
ua-cam.com/video/yXQnydST9fw/v-deo.html
RST Website: www.resystech.com
Support RST on Patreon or UA-cam and earn membership perks:
www.patreon.com/resystech
ua-cam.com/channels/trf6ZiE6hw3k77hGpnuQWg.htmljoin
Follow RST on Facebook:
facebook.com/RenewableSystemsTechnology
A few humble suggestions for your design:
1. Keep the battery pack and motor as low as possible, possibly equal to the line at which the center of the wheels are, it would make a huge difference to handling
2. A storage compartment under the tank maybe?
3. A built in charger for the battery
4. Air channeling using plastic ducts from the front to cool the controller with forced RAM air intake, if the controller is mid-mounted
5. Vintage-style LED headlight would look sweet.
6. A strip on the inside of the frame, just like you did to reinforce the Triple tree stem, for additional support
Good luck with your project! I'm waiting to see more!
@@shubhamchandra5417 1 - the motor is built into the wheel, and the battery will be set according to the ground clearance needed. Center of gravity will be the lowest it possibly can be.
2 - Maybe, if there is room. That area will hide the contactor, converter, and wiring harness. A storage compartment in the rear cowl would be easier.
3 - No room for a built in rapid level 2 charger, which is what I use to charge with. They're larger than most people would think.
4 - No channeling required. This is a naked bike, ie: minimal plastic fairings. The battery, controller and motor are completely exposed to direct air. Cooling is optimized.
5 - Not a fan of big round headlights, see the CAD at the beginning of the video for the LED headlight style I've chosen.
6 - No room - the battery is bolted inside the frame tubing, which adds rigidity. But it's not required anyway, the subframe alone is a steel tank and far stronger than anything on the market that's built with aluminum.
@@JamesBiggar I've seen the CAD for the headlight, I had already assumed you don't prefer Round Headlamps but said anyways
4 - got a point, it's fairly open and I just rechecked, it's just a 12KW motor, at continuous your controller can supply 240A/17.2 kw at 72v, so I'd go as far as leave the cooling alone, what's included should be adequate, even at your 24kw peak, which should draw 335A out of your 600A peak, though i doubt your 60Ah batter would keep up. Is it 10C? Then it absolutely would.
I've got ideas of converting my existing bike (Yamaha R15 V3) to an EV with a built in charger and a 120v 10kw LiFePo battery, the problem is, in my country it's really hard to find a BLDC motor above 3KW, I need one that's at least 15KW, and international shipping is currently unavailable because, you know.
Thanks for doing what I can't, cheers mate
Yeah, that's why I thought it was funny that you suggested I use another style of headlight, because I already made up my mind lol. But it's cool, no big deal bud. The battery can certainly take it. Custom built by Grepow with a peak current draw of 350A, 200 continuous. They can do even better than that for the right price. Affordable mid-drives above 3 kW are hard to find for sure. I personally avoid them because they take up battery space. Hub motor works great, plenty of torque and speed for a street bike, more than most conventional bikes in its class. But not always the best choice. No gearing = no options, wouldn't be a smart choice for a track bike unless it had a built in transmission. I've seen a couple of manufacturers working on such designs with axial flux configurations, but I don't think they're available to the gen public yet.
sir this video alone placed you on top of my watch list. i myself is in the mist of this project. im dealing with all the legal shit for California. im going to throw it out there if anyone can build a Ebike for less than 5 grand thats cali street legal. you will make a killing, Im willing to be a partner with a 100k investment towards a business op.
Nice work you make it look so easy.
I love this build!
Wowww....looks promising bro...waiting for the next episode anxiously..
My friend you did a great job. I like your video. Wish you good on your work
Amazing work....
Waiting for the final product......
good job man👍
Superb waiting for part 2
This guy builds everything ground up. It is so satisfying to watch. Much appreciated if you could share your background, what did you study, where did you work, what inspired you etc
Grew up on a hobby farm. Dad worked as a heavy equipment mechanic during the day. Worked with him a lot when I was younger, fixing machines and putting them to work. Took an interest in woodworking in my early teens, got a summer job in construction. Worked that for a couple of years, 'barely' graduated high school in 2000, started an apprenticeship in 01. Got my red seal cert in 05, started a construction company a year later. Became interested in renewable energy and started experimenting with that in my spare time. Started the YT channel in 2010 I believe (maybe 2009, have to check). Didn't really take off until a couple of years ago - early content was admittedly crap. But things are going good now, I decided last year to do this full time. That's my story. The skills that I learned along the way definitely have helped here, but there was A LOT of research and head scratching involved to get to this point. Fluid dynamics, thermodynamics, mechanical and electrical engineering, etc - none of that was covered in the carpenter apprenticeship. Followed by a lot of mistakes. Building something from a set of plans is one thing, competently designing new tech is a whole other ball game. But if there's one thing that I hope this channel accomplishes, it's proving to others that if a simple carpenter can do this, anyone with the will and ambition can do the same.
@@JamesBiggar Thank you. Your background suggest you have a high level of perserverence. You have certainly inspired me. I am sure there are many more you've inspired. Keep posting the building videos. Thank you again.
Wonderful work
Great job!
Amazing work!!!!!!
Amazing job!
Love u bro seeing all your videos with very interest
what a SKILL...... I'm wondering how to build headtube and how to keep swing's arm shaft in place.... this dude solves them like that! amazing
The project is great! At least no one can complain about the creativity when it comes to the tools available. Man really needs a lathe ;)
Mis respetos, impresionado con tus habilidades, luce genial la motocicleta 👏👏👏👏👏👏 , espero con ansias los siguientes videos , saludos desde Chile.
Very unstoppable greaty hardwork. Amazing
Encore un engin de malade j’adore 👍🏻
Super , good work appreciable 👏👏👏 upload part 2
Brother I congratulate you I love your welding and construction technique, the vision you have of the lines is super futuristic industrial, I love that, your way of editing the video is super nice to see you work. I would like to be able to have some of the machines that you really build although I know that it is impossible. I take off my hat and I congratulate you, a big hug and greetings from Venezuela.
Skills. You gots them!!
Beautiful bike!
Amazing bike please part 2
This made my day...
Cant wait for the next vid
Magique, bravo 👏😊
Noice, thanks for the logo weld blocker...smart, ready for pt. 2
It's not like my tv or monitor is going to reproduce the lumens that the welding was putting off. It's not going to burn my eyes since the reproduction system simply can't. Now, the suddenly loud scratching noise on the other hand...
It's not the lumens that matter from a welding arc - it's the UV light. That's what causes flash burn. But, despite my attempts to convince complainers in the comments of the last video that cameras can't record UV light and thus the flash can't hurt their eyes beyond being bright and irritating, the comments still persist. People don't understand light energy very well it seems, but like to pretend they do lol. The loud scratching noise, on the other hand, shouldn't be perceived as sudden if paying attention and can be rectified by simply adjusting the volume on a person's device ;)
@@JamesBiggar lcd panels in smartphones and computer monitors dont emit uv light at all.
Generally that's true, but irrelevant given that standard cameras can't record UV light any more than they can record infrared - they have to be modified to pick up those wavelengths, otherwise they only capture the visible light spectrum. But I'm sure this won't be then end of me hearing about it. Such a silly topic to drag on. Anyone want to talk about the bike?
@@JamesBiggar Yep me !
Awesome bike mate, I'm hurried to see more of it ;)
Another wicked sick project? Keep'em coming bro!
Why bushing instead of bearings?
Bearings are overkill for low speed applications - that's why the headtube bearings are nothing fancy either. Just thrust bearings in Teflon. Bushings are ideal for high load/low speed or or high speed/low load applications - the right bushings for the right application will last just as long as bearings but for a fraction of the cost. This is why you won't see expensive bearings used in things like heavy digger booms. Low speed, high load, so they just use bushings welded to the ends of the cylinders. Roller bearings are best suited for high speed/high load uses, like a wheel bearing. A motorbike swingarm is a low speed/high load component. These bushings in particular are rated for 2000 lbf/sq.in dynamic load, far more than what they'll ever experience with me and a passenger driving in normal road conditions. www.fastenal.com/products/details/0435438
Excellent. Thanks.
Your perfomance is very good
wow, thank you sir, for blocking that bright spark, i think your the first one to make that extra effort.
he aint even plaaayinng bro!, whaaat!!😝😎👌✨🛠
I love how you block the weld plasma with y our logo!!!
*_edit:_* Also ... I ride an all wheel drive electric bicycle. I have 2 separate batteries for each hub motor. I was thinking, you could do this on this bike if you halved the wattage of the rear hub motor, and used an identical wattage hub motor for the front wheel. Then you could tie it in to the same battery bank and still get almost the same performance. It also makes for much more fun when going through mud/water puddles that a one wheel drive bike would have issues with.
I've won lots of bets with my setup LOL!!!
Superb !!!!!!
Wicked. Just Wicked!
very nice dude
HOLY SHIT, THIS PROJECT IS INSANE, SUBSCRIBED ...want to full project.
Spectacular! Subbed here!
excellently good
Nice job
Keep going
Superb build. Would be even better in alloy. Looking forward to you getting some "sponsored" upgraded equipment 🍻👍
this is so fucking inspiring, I would love to do a project like that but I don't have time(school and work) nor the space to do it (still lives with parents rip) or the money. can't wait for the part 2 !!
looking shweet!
Только RESPECT за работу
Another one! 👍🏼👍🏼
Good job.
Best of the best bravo
I bealive in love again :')
You are a legend
I love that you are covering the sparks with your logo. It helps our eyes. Thanks man 👏
amazing
Wow, good job bro, I will definitely subscribe you, right now
I love your channel...
Super!
Очень круто!
Nice 🤩👌
BAD ASS!!!
I want to learn from you plz make videos in parts which helps us to learn. Your are doing Awesome. ♥️ You sir.
TALENTED
I`ll translate from our language one frase: dude you`ve got golden hands
Super!
From Viet Nam with love!!!
Cant wait to see more, just subs btw
I love it.......that's my tip.......😃😃😃😃😏
Thanks 😍
Hi, you can find out what did the 3d model on the computer use?
Great job... Can you share the blue prints if you have.?
Are plans available for this build? I would love to have one
what you use to cover the battery area which material used and how to make it plz reply me
Criativo excelente