Fillet braze the top tube extension to the chopped electric bike frame

January 5, 2010 · 1 comment

In this video the top tube extension is fillet brazed to the frame. This completes the frames structural components. The flux will need to be soaked off and the fillets sanded down smooth. The frame will need to be painted once the rest of the fabrication is complete. The painting will wait for some test rides to make sure my brazing is adequate and the frame holds together.

The extension will allow the batteries to be mounted lower. The next step is to fabricate the battery box and hang it in the newly created space in the frame.

This project is getting close to completion. I’m looking forward to seeing how my ideas for improving the ride of this electric bicycle work out. There are several details to complete and I will share them here.

I’m starting to think of what the next project will be. I have several ideas but would like to hear what you would like to see me build. This could be anything from a complete bike design and fabrication or another chopped project like this one or even an ebike conversion kit installation. Should it be a cargo bike, a diamond frame bike, a recumbent bicycle?

Leave a comment and let me know what your interests are. I’ll be sending out a survey soon but go ahead and let me know what you like in the comments and I’ll include them in the survey.

{ 1 comment… read it below or add one }

1 John January 6, 2010 at 9:24 pm

I’m interested in how to retrofit my commuter bike with an electric assist motor. I’m not getting any younger, and I don’t want to deal with a car.

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