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The summer after I graduated high school I still didn't have a drivers license and wanted a better way to get around, I decided I would build a (35mph) 48v 2500W E-bike using one of my old bike frames, this bike wasn't my prettiest or my proudest project but it worked well at got me to and from the gym, even though it may have made me look like a crazy person.
For the V1 build I:
I mounted a throttle, a display, a battery, motor controller and motor onto my bike frame
Attached reinforcements to my bike frame to handle the new wheel torque it had to handle
Soldered, heatshrinked and crimped wires together
Did a really bad job making it look pretty
V1 of the Illegalmobile E-bike
A year later the bike (unsurprisingly) broke down, the rack I had mounted the battery and controller on (with zip ties???) was not strong enough and snapped, on top of that the rack when it broke had pinched the wire between the moving wheel and itself when it broke causing the wheel to rip through the wire.
I decided to make the bike more reliable with this repair, I:
Remounted the battery and controller in the center of the frame of my bike using a custom machined metal bracket and screws (not zip-ties)
Repaired the ripped wires
Fastened the wires in a more organized way, keeping them running along the frame, eliminating wire sag
I liked the E-bike but wanted something a little more powerful so I have started working on an E-Dirtbike
These are the things I'm currently working on with the new E-Dirtbike:
12kw motor custom mounted onto a frame not meant for it
Assembling a 288 cell custom assembled 24s12p with a BMS battery (88V) having to work around battery area being larger than space available in the frame
This project is much harder requiring the design to be able to withstand the force generated by a motor of that power and the speeds it will produce
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