Electric Motorbikes Build (model)

[connorwmc]

Hi,

This is my electric motorbike full-scale model build, Yes, A model.

Hopefully, a few people will be interested and follow the build.

As part of my design course at University, I am required to build a full-scale model, and if you haven't guessed it, I have chosen to design a custom electric motorbike.

Unfortuanty it won't be a running and working model as my student budget doesn't stetch that far.

Please bare in mind the bike is being built as a model with a hint of realism and won't be load bearing.

[Mr Fro]

I am interested. You may proceed.

[connorwmc]

Ive decided to use a donor bike as it will allow me to recycle a lot of the parts to use on my model.

The build i have managed to get for cheap is a recovered AJS 125.

 

 

I have had to removed the tank, fairings and engine at home, before i can transport it to Uni (heath and saftey)

 

[mealexme]

Just a hint, but putting the rear wheel back on might help with transportation

Looks like a fun build. But if is a non-working model, it will be interesting to see what you come up with, since your making essentially an electric bike, without the motor.

How are you planning on building it? With bits from other bikes or are you custom-making parts?

[Joeman]

Just a hint, but putting the rear wheel back on might help with transportation

Looks like a fun build. But if is a non-working model, it will be interesting to see what you come up with, since your making essentially an electric bike, without the motor.

How are you planning on building it? With bits from other bikes or are you custom-making parts?

 

a non-working model of an electric motorbike based on a petrol powered donor bike... so basically a petrol bike with its engine removed??

[mas101]

Is this a design course? an engineering course?

As above, I'm struggling to see the point of this. If you're into the aesthetic design then you'd not start with an existing frame would you?

[connorwmc]

Is this a design course? an engineering course?

As above, I'm struggling to see the point of this. If you're into the aesthetic design then you'd not start with an existing frame would you?

 

Its a design course. The point of using an existing 'Frame' allows me to use all the existing mounting points 'swing arm' 'forks' and adapt the frame to suit my design. I am currently in the process of cutting and welding the frame, once that is complete, custom body panels will be made to suite the design. I have already designed and come up with concept visuals in photo shop, i have over laid my design onto existing blue prints of the donor bike and found it is a suitable 'base' to start with. I have also done a full tape drawing of my design over the existing donor bike which will allows me to make an accurate model. Hope that helps

[connorwmc]

Just a hint, but putting the rear wheel back on might help with transportation

Looks like a fun build. But if is a non-working model, it will be interesting to see what you come up with, since your making essentially an electric bike, without the motor.

How are you planning on building it? With bits from other bikes or are you custom-making parts?

 

Most parts will be custom made from blue styrofoam (modeling foam) and then body filled ( or simular ) before painting/ wraping the model to give a realist finish.

[CGD217]

Well good luck with the course fella and don't forget to get some pics up along the way.

Sent from my iPhone using Tapatalk

[connorwmc]

The first task was to cut, chop and weld the existing frame into a frame that is more suitable to build my design on.

 

 

i was able to tape draw my design over an existing blue print of the donor bike, this was so i could using existing reference points from the donor bike.

 

 

After a short time in the metal workshop the angle grinder made short work of the old metal. ( at this point i had so many ideas for a bobber style bike ) but unfortunately had to stick to my original plan.

 

 

After a lots of cutting,measuring,chopping and welding to bring life to a new style of bike, i realised i made a few errors on the seat height ( forgetting to take into the account a seat needed to go top) but ill cross that bridge at a later date.

I had to drop the forks through the yokes to get the bike to sit at the right height and gives the bike a overall better stance. but now I’m unsure on how to re-attach the hand bars? could i get a spacer ? Don’t really want to use clip on handles.

[connorwmc]

the plan now is to board out the metal frame ready to apply modelling foam to form the bike to its new shape.

 

 

so after a lot of thinking and measuring and more thinking.... the angle grinder came back out and i re hacked the frame, this was to improve the seat height and also to make boarding out a lot easier.

\

 

i am a lot happier with the overall structure now

[Stu]

If you are building a scale model

why have you hacked half of the frame away?

I would have thought you would have had it structurally sound so if it was made then you wouldn't have to redesign the frame again

[Mr Fro]

You have been a touch... bold with the chopping!

Can you weld the frame/head bit back in again? You could use some bracing on the seat bit too.

[connorwmc]

If you are building a scale model

why have you hacked half of the frame away?

I would have thought you would have had it structurally sound so if it was made then you wouldn't have to redesign the frame again

 

Good point, the frame on the donor bike conflicted with my design. As you probably know all bikes have different frames, although i agree many are similar in structure i cant let a previous bikes frame govern my design. In 'reality' there would opportunities to work closely with engineers to make a structurally sound frame for the design but at this point ,the model is purely for aesthetics and will not be weight bearing.

[Stu]

So in the end you are going to have to build a frame to suit the engine (electric motor) which could easily scupper your plans for the design of the bike

But that is the idea of doing this sort of project its all about design, trouble shooting and the final product

[connorwmc]

You have been a touch... bold with the chopping!

Can you weld the frame/head bit back in again? You could use some bracing on the seat bit too.

 

It was a risky move! i removed the forks and hoped it wouldnt collapes under its own weight when i cut through the frame Ive slightly braced the head tube part with a 3mm plate and keeping my fingers crossed thats enough (for now at least).

[connorwmc]

So in the end you are going to have to build a frame to suit the engine (electric motor) which could easily scupper your plans for the design of the bike

But that is the idea of doing this sort of project its all about design, trouble shooting and the final product

 

Very true! haha the data i've used for the dimensions of components such as motor and batteries, are from the KTM E-ride and design around that accordingly but as you say I'm sure the frame design would be based heavily on the structure and the support for those parts and less to make it look pretty! but yeah, i am just trying to make a cool concept model to portray my design

[RantMachine]

If you are building a scale model

why have you hacked half of the frame away?

I would have thought you would have had it structurally sound so if it was made then you wouldn't have to redesign the frame again

 

Good point, the frame on the donor bike conflicted with my design. As you probably know all bikes have different frames, although i agree many are similar in structure i cant let a previous bikes frame govern my design. In 'reality' there would opportunities to work closely with engineers to make a structurally sound frame for the design but at this point ,the model is purely for aesthetics and will not be weight bearing.

And to be fair, that subframe has about as much support as the subframe on a KLX250 or CRF250L

[Joeman]

the plan now is to board out the metal frame ready to apply modelling foam to form the bike to its new shape.

16129370_1229852487082673_1399261451_o.jpg

 

 

spot the difference: