E-Bobber build
 

I decided it was time for a new bike, this will be my sixth build, my forth with a custom frame. I wanted to build the entire bike this time, including the forks/handlebars as well. This will be my most ambitious build to date. Staying within a limited budget I opted for the Magic Pie 2, 24" x 65mm wide double wall rims, Kenda Kraze tires, 8" discs (which will be matching) with Avid BB7 calipers.
http://i190.photobucket.com/albums/z...%20800x531.jpg

Central section of fork is done, used thrust bearings on either side of the main pivot. I devised a clamping system to attach my own bars.
http://i190.photobucket.com/albums/z...%20800x540.jpg

Fork legs finished after a bit of weld clean up. As I don't have facility to do TIG I opted to ground things smooth.
http://i190.photobucket.com/albums/z...%20800x525.jpg

The finished fork compared to the somewhat less beefy Schwinn style inspiration.
http://i190.photobucket.com/albums/z...%20800x547.jpg

As the fork will have covered drop outs/pivots, I decided on a similar treatment for the rear. You can do a lot with an angle grinder, drill and files.
http://i190.photobucket.com/albums/z...%20800x531.jpg

Mocking things for size/clearances in my uni-strut jig. It's not laser straight but really helps to keep things in alignment.
http://i190.photobucket.com/albums/z...%20800x527.jpg

Forming the lower chain stays
http://i190.photobucket.com/albums/z...%20800x532.jpg

First time sitting on it's wheels, mocking up the seat position.
http://i190.photobucket.com/albums/z...%20800x531.jpg

Battery/controller rack built. To power the lights there's a mount for the DC-DC converter under the Controller. I've opted for a Greentime 3000 watt, 80 amp controller with a 48 volt, 30 amp/hr battery made from Samsung 18650 cells.
http://i190.photobucket.com/albums/z...0800x531_1.jpg

OCD :D

Here it's shown with second attempt seat mount as the first style didn't flow as I wanted. Discovered that my air shock was too dampened (non adjustable) so changed it out for a small coil spring style.
http://i190.photobucket.com/albums/z...%20800x559.jpg

Headlight and Cycle Analyst mounts finished today. Gyes leather grips arrived in the mail. Bars will be trimmed to final length after test fitting all the controls.
http://i190.photobucket.com/albums/z...%20800x515.jpg

http://i190.photobucket.com/albums/z...%20800x520.jpg

http://i190.photobucket.com/albums/z...%20800x514.jpg

http://i190.photobucket.com/albums/z...%20800x551.jpg

Built the mount for a tail light under the seat, bottom bracket gussets, rear fender mount (not seen here) and the securing straps for the battery this weekend.
http://i190.photobucket.com/albums/z...s/DSC_0415.jpg

http://i190.photobucket.com/albums/z...%20800x531.jpg

OCD :thumb:

A little update but progress has slowed due to the sub zero weather here at the moment. I'll need to stoke the woodstove to get any amount of work done if this keeps up. Rear fender mount finished and used the rear fender flipped around from the Simply Red build to mock up the look. I will likely make new fenders front/rear without the flat section at the end. Still kicking around ideas for a kick/centre stand and front fender mount. Hopefully warmer weather this weekend.
http://i190.photobucket.com/albums/z...%20800x522.jpg

http://i190.photobucket.com/albums/z...%20800x531.jpg

I've been working on the fenders and other woodwork for this build. Here's where we're at... the fenders are made from 2 layers of 1/8" Baltic Birch plywood. As I'm not using a two part form for the lamination, there's a certain amount of spring back, it took a couple of tries to get the correct radius to keep the fender tight to the tire.
http://i190.photobucket.com/albums/z...%20800x531.jpg

http://i190.photobucket.com/albums/z...%20800x550.jpg

http://i190.photobucket.com/albums/z...%20800x531.jpg

OCD

Decided to add a forkstop to the build. Used a suspension snubber and tapped a disc for the 3/8" mounting stud, should save some wear and tear on the cables.
http://i190.photobucket.com/albums/z...0800x532_1.jpg

http://i190.photobucket.com/albums/z...%20800x518.jpg

Finished the front fender mount and mocked up the side panels
http://i190.photobucket.com/albums/z...%20800x531.jpg

http://i190.photobucket.com/albums/z...%20800x524.jpg

OCD :thumb:

WOW... Dude, if that E-Bike works 1/2 as good as it looks, it will be some E-bike... :thumb:

Mad skills; great looking bike. Congratulations.

Wow! You are doing some nice work. Check out italjet and https://www.electricbike.com/italjet-ascot/ for some more inspiration. These guys make hub and mid-drive models with a similar look. Look forward to seeing a video of you ripping up the pavement. ;)

Weather's been cold up here north of the border, finally managed to get a couple of coats of paint on this project...time to put it together http://www.ratrodbikes.com/forum/sty...smilies/41.gif

http://i190.photobucket.com/albums/z...%20800x498.jpg

This is my first post on here. Great job! Looks like an awesome ride. :thumb:

Thanks Roy:
Glad my build inspired you to post for the first time...

Which hub motor is that? I'm in the process of converting one of my bikes.

Hi Roy:
It's a Golden Motor Magic Pie 2 which is the model that has the external controller. I've coupled that with a 3000 watt, 80 amp controller and a 48 volt 30 amp/hr pack. This combination should give me about 60km range per charge (if I don't pedal much) and a top speed around 54km/h. You will need to use some disc brake spacers to get enough clearance for your caliper (if you run Avid BB7's which I highly recommend).
:giver:

Updates: Now in colour! Needs a chain, connect the brakes, wires and ride! :speedy:
http://i190.photobucket.com/albums/z...%20800x512.jpg


http://i190.photobucket.com/albums/z...%20800x526.jpg

Gorgeous; where's the waiting list for when you start producing them?

I'll start taking orders when I find someone else willing to work for $.75/hr. :p
Thanks for the compliment.

Good one, but how come you're making about 3X what I earn on my projects?

He's making $0.75/hr and you're making $0.25/hr more than I do on my projects... Mine usually co$t me money per hour, but the payoff is having something beautiful and unique.

Great job on this beauty! :thumb:

Wow. Just wow. Very inspiring. :)

I should have been more specific; $.75Cdn = $.25US...or soon will if we can't wake our economy up. :cry:

Great build! lot's of photo's for us to follow the build process. Love the wooden fenders. Looking forward to hearing as to how it runs.

Thanks Bob:
I need to finish venting the front cover and door for the battery box, then another coat of paint before I can glue them on. I don't want to cook my controller due to lack of airflow, even gives me a chance to drill a few more speed holes. I'm looking forward to seeing what the power difference between the Magic Pie 2 and the Golden Motor 901 hub motor is. GM claim the larger diameter gives more torque per watt, but we will see. :innocent:

No posts for a month or two. Where does the "Electric Pumkin" stand now? :lol:

Ohhh, that's a bit of a story. The "pumpkin" is actually bright red (think Tremclad red) and is finished apart from the rear drop out covers and performing well. My first MPII from Golden Motor lasted for two, twenty minute rides and came to a grinding halt. Turns out a couple of the magnets were not glued down well and rubbed on the stator which cooked the windings. GM Canada took exception to me opening the motor to find out why and threatened to not cover the warrantee because I posted video on Youtube so he could see what the issue was. As I have previously worked as a motor rewinder doing 1/10hp to 100hp electric motors, I felt confident pulling this 'toy' apart. Anyway, after sorting that out Canada Post delivered the new motor a week late (he actually did not end up wanting the old one back) it took a couple of weeks to get the bike finished and rideable, some crappy west coast weather followed and I've been commuting on it since. I'll post some updated pics when I get a chance if the weather cooperates. Thanks for remembering my build. :thumb:

I love your build! The somewhat old school classic motorcycle look is the way to go for a throttled cruiser ride IMHO. My brother is a welder and teacher with certs galore. I showed him your project and the Italjet's. He especially liked the double top rail chrome Italjet prototype (don't see it for sale anywhere?) which looks very similar to yours; just all blinged up (he's a Harley guy - new 2016 CVO Street Glide).

He wants me to design a Bobber build and offered to weld it up for me. Not sure I have the spare time for such a project inbetween the other many projects and honey-do's, but I'd sure like to.

Funny you mention the problem you encountered right off. I was on about my third or forth eMTB ride off-road with two friends on a full suspension non-electric MTB's. They were smoking me down hills, but I raced right back by them on every up hill. I had just passed them on a flat area after a decline and my bike started making this screeching noise and became hard to pedal. They were laughing as they passed back by me riding slow trying to figure out what was happening. I think they even threw a couple snide comments my way; something like "Did your electric cheating machine breakdown?"

After stopping and starting a couple times without the screeching ever going away, we all stopped to get more eyes on it while I cranked it with the rear wheel off the ground. Then I spotted the problem. A stick had wedged itself between the electric motor and the front chainring making an aweful sound and putting resistance on the pedals.

That gave me a big sigh of relief, as I thought I might have somehow fried something or had some other China part go out on me. All that worry and it was just a twig in just the right spot!

I'm approaching 600 miles now without any problems whatsoever and my MTB friends are now considering getting eMTB's too...