An electric bicycle is much easier to build than you might think! All you need is a properly working bike, a conversion kit and a battery. With the help of a conversion kit, the process becomes super simple and fast. And if you're shopping online to find the best deal on the kit and using a bike you already own, this can be an inexpensive project.
Steps
Part 1 of 3: Gathering the material
Step 1. Choose a mountain bike with front disc brakes and wide handlebars
If you don't have a bike yet, search online or in your area for a used bike at a good price. Fortunately, you can use just about any bike you have on hand, although certain features will yield the best results:
- Choose a bike with 26", 20" or 16" wheels as these are the most common wheel sizes. The smaller wheels are usually found on folding bikes and will accelerate faster, ride bumpier, and be less efficient at cruising speed.
- Mountain bikes are most often converted to electric bikes, although you can use another type as long as it has a strong frame and a standard pedal drive. Do not use a bicycle with a carbon fiber frame or forks, as they are not strong enough to handle the additional weight or torque.
- A wider handlebar is best, because then you have enough space for all your accessories and lights.
- Front disc brakes make it easier for you to stop on steep slopes.
Step 2. Buy an electric bicycle conversion kit
A conversion kit makes the process much easier, especially if you've never built an electric bike before. These kits include accelerator pedal, speed controller and hub motor wheel. Some also come with gauges, displays and brake levers, although these are not strictly necessary.
- Make sure the kit comes with a wheel that is the same size as the wheels on your own bike! Because of the location of the gears, it is much easier to replace the front wheel than the rear wheel. That is why you should opt for a kit where the hub motor is on the front wheel.
- In most cases, the battery is not supplied with the conversion kit. However, for ease of installation, it is best to purchase the battery and conversion kit from the same manufacturer.
Step 3. Choose a 36 or 48 volt battery with a capacity of 10Ah or 20Ah
Choose a battery designed for use on an electric bicycle, as it comes with a charger and is much easier to install. Make sure the voltage and capacity of the battery you choose is suitable for the conversion kit you have purchased. The higher the voltage of the bicycle battery, the more powerful the bicycle will be. If you're building an electric bike, opt for a 36- or 48-volt battery to allow for speed and comfort.
The capacity of the battery determines how long it will last. A 10Ah battery is suitable for short trips, while a 20Ah battery offers you extra capacity for slightly longer trips
Part 2 of 3: Replacing the wheel
Step 1. Disassemble the wheel you need to replace
Start by opening the rim or cantilever brake using the lever (if applicable). If the bike has disc brakes, remove the locking pin or cotter pin or the clips or springs that hold the brake pads in place. Pull out the brake pads with a pair of pliers and set them aside.
- To remove the front wheel, turn the bike over so it sits on the saddle and handlebars, then flip the quick release to 'open'. Then lift the front wheel off the bicycle.
- Squat behind the bike to remove the rear wheel. Hold the frame with your non-dominant hand and use your dominant hand to pull the derailment back. Then lift the bike frame up and off the rear wheel with your non-dominant hand and loosen the chain with your dominant hand.
Step 2. Transfer the tire and inner tube from the old wheel to the new wheel
Drain the air from the old tire and use a tire lever to separate the tire from the wheel. Pull off both the tire and the inner tube. Install the tire and inner tube on the wheel supplied with the conversion kit in reverse order.
Step 3. Place the wheel with the electric hub on the bicycle and connect the brake parts
To put the wheel back on, reverse the process you used to remove the wheel. Be sure to adjust the chain to fit properly when you replace the rear wheel. If the bike has rim or cantilever brakes, simply close them over the new wheel using the lever. If the bike has disc brakes, replace the brake pads and secure them with the clips, springs or cotter pins.
Adjust the brakes as needed, either by aligning the brake discs (for mechanical brakes) or by pumping the brake lever (for hydraulic brakes)
Part 3 of 3: Adding the other electrical parts
Step 1. Install the speed controller and throttle
Follow the instructions in the conversion kit to install these two parts using the supplied hardware. Use the supplied bolts to attach the speed controller to the bicycle frame above the chain. Then attach the throttle to the handlebars for easy access.
If you have any other accessories, please attach those as well. Attach the speed sensor to the rear wheel and connect all displays and gauges to the supplied hardware on the handlebars
Step 2. Connect the battery to the speed controller and throttle
Follow the instructions that came with the kit to connect each part. Typically, you just need to connect the speed controller connector to the battery connector, then repeat the process for the throttle. Be careful not to touch the battery wires, as that could cause a dangerous spark!
Step 3. Mount the battery on the bike
Most electric bicycle batteries are designed to fit on the frame, in place of the bottle holder. This is the ideal place because it keeps the center of gravity low. Use the supplied hardware to attach the battery to the frame as indicated in the instructions that came with the battery.
Alternatively, you could place the battery in a box or basket at the front or back of the bike, especially if it's too big to fit properly on the frame (for example, if it's over 60 volts)
Step 4. Secure all loose cables
Use tie wraps to secure all loose parts to the frame. Think about safety, because you don't want cables to get caught while driving.
Step 5. Ride your electric bike
That's all! You can now enjoy cycling on your electric bicycle. Just gently press the accelerator when you're ready. Take a test drive in a less populated area so you can get used to it before hitting the road.
Step 6. Charge the bike when needed
The battery of the electric bicycle comes with a charger, which makes the process quite simple. Follow the instructions for connecting the battery to the charger and plug it into a suitable outlet when needed.
Tips
- Accelerating hard consumes the battery the fastest, especially from a standstill.
- You can also build an electric bike by adding a mid-mounted motor, but this option is more expensive and involves a lot more.