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.


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.


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.


The finished fork compared to the somewhat less beefy Schwinn style inspiration.


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.


Mocking things for size/clearances in my uni-strut jig. It's not laser straight but really helps to keep things in alignment.


Forming the lower chain stays


First time sitting on it's wheels, mocking up the seat position.


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.


OCD

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.


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.

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.




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The kickstand is the part I usually skip on a build and then regret later as I'm searching for somewhere to lean the bike against.


Lugs welded into position and lower frame tube capped.






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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.

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.






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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.




Finished the front fender mount and mocked up the side panels




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

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

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

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).

Updates: Now in colour! Needs a chain, connect the brakes, wires and ride!

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.
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!

Wow. Just wow. Very inspiring.

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

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.

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