How I skinned my electric bike battery box part 3

April 30, 2010

This is the final video of the battery box fabrication. It shows soldering the internal charging connector, installation of the batteries, and final installation of the box on the bike. The battery box started as a prototype for future boxes. It has turned out nicely and I’ll use many elements of it for future projects. [...]

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Bicycle frame building class is over

April 27, 2010

The chromoly brazing frame building class is over. The United Bicycle Institute course was one of the best I have ever taken, I recommend it to anyone who wants to learn how to design and build bike frames. My knowledge and skills in this area have increased dramatically. I can now design and fabricate a [...]

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Bicycle frame building class day one

April 12, 2010

I started a frame building course at United Bicycle Institute where they teach how to design and fabricate a bicycle using chromoly tubing and brazing . Today I learned how to braze a water bottle boss, miter a tube for a lug, and lug brazing. The photo shows my first attempt at a lug braze. [...]

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Next electric bike project idea

April 8, 2010

It’s time to start some new projects. I have two projects in mind. The first is an electric recumbent cargo bike. The second is a small commuter bike that I’m calling ShortHopper that you can follow in that Category. I’ll be posting blogs about both projects. I’ll start with ShortHopper. This bike will look something [...]

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How I skinned my electric bike battery box part 2

March 18, 2010

This video is a continuation of the battery box fabrication. It shows the lid fabrication that has lots of angles, bends and notches. It turned out really nice I think. My new press brake tool worked out really well. I used it to bend the sides of the lid. The next and the last video [...]

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How I skinned my electric bike battery box Part 1

March 9, 2010

This video shows the final steps to the battery box fabrication. I added aluminum panels to the frame. This makes it look really nice and protects the batteries and wiring from the weather. It also makes the battery box look like an integral part of the bike and not like a mad science project gone [...]

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Adding a skin to the battery box frame

February 28, 2010

I’m finishing the battery box for the chopped mountain bike project. This is one of the last major projects I need to finish before I can put this bike back into service. If you want to see which electric bike this battery box is going on, you can view the first test ride video by [...]

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Chopped electric mountain bike nears completion

February 9, 2010

It’s been awhile since the last update so I thought I would make a post to let you know how it’s going. As usual, it is taking longer than expected. The paint for this electric bike frame is still curing. I started the re-assembly this evening. It’s going to get new brakes and levers. I’m [...]

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Chopped electric mountain bike test ride

January 29, 2010

The major fabrication is complete and this electric bike is assembled for the first test ride. I’m really happy with the way this project turned out. So far all of the changes I made and the expected improvements have proven to be good. The bike rides and feels really stable and strong. Moving the batteries [...]

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Assembly of chopped mountain bike project started

January 22, 2010

The assembly is well underway and it’s exciting to see it all coming together. I still need to install the brakes, derailleurs, chain and wiring which will reveal some problems that need to be solved. I don’t anticipate anything major though. Once it’s together I get to go for a ride and see how it [...]

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