Building An Electric Motorbike…Out Of Plywood?

Building An Electric Motorbike…Out Of Plywood?

Get the plans for this project here: https://renewablesystemstechnology.com/electric-motorbike.html

This was by far one of my favorite builds. Everything went well, and the bike works great! As you can see in the video, the roads around here are so bad we’d almost be better off going back to dirt and grading it once a month instead (I had to drive on the shoulder of my street – that’s how bad it is). They’re rough, full of pot holes and raised culverts, and are a good test for the structural integrity of this bike. After 200+ km’s, so far I’ve had 0 problems and don’t anticipate any popping up in the future. This bike is solid. Its frame is basically a fiberglass reinforced glue-laminated beam, after all.

When it comes to weight, the frame is ~60 lb, and the bike in total weighs 120 lb. This is comparable to the LMX free ride motorbike which weighs 100 lb. A motorbike with an equally sized engine in terms of hp (100-125cc = ~6-8 hp at 1hp per ~15cc avg) will weigh around 200-250 lbs, so this bike has a big advantage in that regard.

The motor is rated for 3000 watts continuous output, 5000 watts peak. It has loads of torque (max 85 Nm) for accelerating and climbing steep hills, a lot more than what I need. Top speed is rated at around 90 kph, but I’ve only had it up to 80 kph on these roads – they’re just too rough to go beyond that for a novice like me, I’m still getting used to driving that fast on two wheels lol. Regardless, it has no trouble keeping up to traffic or overtaking slow drivers, if need be.

The battery consists of ten lithium 40V/5Ah Greenworks yard tool battery packs, which are wired in a series-parallel configuration to create a 72V/25Ah bank (nominal voltage for the packs is actually 36V) – I kept the leads from the batteries to the terminal blocks exactly the same length so that the internal resistance is the same in each, that way the packs are all charged and discharged equally and maintain a perfect balance between them at all times. They have a BMS built into them, so that really minimized the job of making the bank. I’ve been using Greenworks yard tools for a few years, so I figured the versatility of using their battery packs with this bike would pay off. They were close to the same cost as purchasing individual 18650’s, so the choice seemed like a no-brainer to me.

In the video I take the bike for a ~35 km round trip from home to town and back, which took around 40-45 minutes and only used around 60% of a full charge (the time lapse of the trip is sped up quite a bit to save time, so use the speed settings in the Youtube player to slow it down if you have trouble seeing the speed and power input on the display screen). If I pushed it to the limit, I could probably get between 45-50 km’s per charge on avg terrain. Ideally, to make the battery life last as long as possible, they shouldn’t be drained more than 75% before recharging. This could mean the difference between replacing them in 2 years vs 10 years.

In total this project cost me around $2000 (Canadian): $600 for the motor and controller, $900 for the batteries, and another ~$500 for the suspension, plywood, fenders, lights, etc. Some parts are recycled from my old downhill mtb too. For comparison, to buy a 3000W electric motorbike – like the LMX 161-H for example – would have cost me $7800 Euros, or nearly $12,000 Canadian! That’s not gonna happen lol.

Specs:
Power: 3000W continuous, 5000W peak (~4 – 7 horsepower)
Weight: 120 lbs (54 kg)
Top speed: 56 mph (90 kph)
Range: 30 miles (~50 km), average terrain

Wheelbase: 53”
Head tube angle: 66°
Suspension travel: ~180mm
Wheels: 26”x3” front, 26”x3” rear
Seat height: ~35”

Controller: 72V/60A
Motor: brushless hub motor
Battery: 72V/25Ah

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Readers Comments (50)

  1. حسین عسکری May 9, 2021 @ 12:49 am

    سلام عالی دمت گرم خلیی خوب هست من دوست دارم این طوری باشه دوچرخ اوکی

  2. Sunarkar Nagaraj May 9, 2021 @ 12:49 am

    How much cost for do this bike 👍

  3. сергей нохрин May 9, 2021 @ 12:50 am

    молодец!

  4. are his creations for sale?

  5. Iya ya Allah.

  6. Es una belleza

  7. Jeejendra cricket May 9, 2021 @ 12:59 am

    How much price for this

  8. Shrawan pratap May 9, 2021 @ 12:59 am

    Kitne ki hai

  9. Đã đăng ký kênh , ủng hộ bạn, cùng giao lưu kênh nhé bạn.
    Subscribe to channels, support you, make friends, subscribe to your channel
    G

  10. Can you do this one for me please I pay you

  11. Very impressive, you should making special orders!

  12. This guy is a genius

  13. SCORPION FIRE May 9, 2021 @ 1:10 am

    When I heard Santa Claus had a wooden sleigh, I didn’t know they were talking about this guy

  14. Well done, good job.. now put some hydraulic brakes on that thing.

  15. Good job James!

  16. Nice please call me 9106592977

  17. Well done Sir, Amazing Excellent what fantastic workmanship. how much would it cost for me to buy the finished bike from you? all the best from Robert UK London

  18. very impressive build. just plain simple very nice.
    i recommend using a LED lightbulb just so save some extra energy of the batterys.

  19. Charlie John Antonio May 9, 2021 @ 1:17 am

    Wow

  20. I went looking for ideas for an ebike battery/controller box and found this… You sir are now my hero!

  21. مقتدى البصراوي May 9, 2021 @ 1:17 am

    علتب

  22. Antonio Almeida May 9, 2021 @ 1:18 am

    Perfeito trabalho

  23. I give you a big Sur. You are the best diy Maker

  24. RIL3Y 3R12TA May 9, 2021 @ 1:19 am

    What electric components did u use I wanna turn my 7 yr old mountain bike to this

  25. Mohan malbal May 9, 2021 @ 1:20 am

    Nice video is Bike ka Kitna Dam hai

  26. Carlos Tapia May 9, 2021 @ 1:20 am

    Wheight?.

  27. Артем Вовк May 9, 2021 @ 1:20 am

    What you are doing is amazing! I express you great respect from your like-minded people from Russia!

  28. Jeyaraj Kichu May 9, 2021 @ 1:23 am

    That gas cap…♥️♥️.,. Perfect skilled man…

  29. WOW!!! THE BEST!!!!!

  30. Nice work! I love all of that new curbing with the lousy roads. LOL How they do it here too in places.

  31. I’m from India.

  32. thanks for all, please how you did electric motor or where buy it

  33. Graphic Design May 9, 2021 @ 1:27 am

    Это мопед_Рига 12)

  34. Metal Detecting Tours Georgia May 9, 2021 @ 1:28 am

    Beautiful bike, very intelligent build using everyday materials, AWESOME!!!!!

  35. Slow clap, my fellow Canadian. Well done indeed. Bike is great looking and apparently, performing too. Bravo!

  36. Slizer Princecool May 9, 2021 @ 1:33 am

    Good work dude

  37. John Tserpelis May 9, 2021 @ 1:34 am

    The store said oh the bike cost $4000. This guy said hold my beer and built his own for a fraction of the price.

  38. Thermal Boy Chandan May 9, 2021 @ 1:37 am

    Give me the bike broooooo please

  39. This guy is very talended

  40. Cian O'malley May 9, 2021 @ 1:38 am

    That’s awesome man. Does this reduce any weight? Or could you build this bike in aluminium?

  41. Like the mosquito a wood framed piece of art. Would love one in clear epoxied first grade ply, defo nicer than Sur Ron. Reminds me of wooden bicycle at Trev Deeley museum.

  42. Hriday Pradhan May 9, 2021 @ 1:40 am

    I love everything about this bike! Could you please change the headlights??

  43. Омг. Деревянный байк гг

  44. Akash Hariprasad May 9, 2021 @ 1:42 am

    Man this guy is extremely talented..🔥

  45. Masood Ahmed May 9, 2021 @ 1:43 am

    The most talented and creative person i have met in this world.

  46. sanjay kumar May 9, 2021 @ 1:44 am

    I want to buy this is it available online cost ?

  47. Pure craftmanship

  48. VERY PROFF 😉👍🇩🇰

  49. Do you know how big the wheels are?

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