Battery box for chopped mountain bike project is fabricated

January 15, 2010

The battery box for the chopped mountain bike is fabricated and ready to mount to the frame. This will allow the batteries to be moved from the rear rack to below the seat. This box is a little heavy but is very strong. I can always come back later and lighten it up by drilling [...]

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

January 5, 2010

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 [...]

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Top tube extension for chopped electric bike project is finished

December 29, 2009

The top tube extension is ready to braze. It took lots of filing by hand to fit the tubes. It’s important to make a very close fit. I positioned the existing water bottle bosses so they can be used for mounting something to the top tube extension. So what’s left to do to finish this [...]

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Fillet braze the chopped electric bike chain stays to the bottom bracket

December 23, 2009

In this video I finish fitting the chain stays to the bottom bracket, align the frame using the jigs I made, and fillet braze the chain stays to the bottom bracket. I’m now one more step closer to completing this project. The next step is to finish fitting the top tube to connect the rear [...]

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This vise is from Galaxy 5

December 20, 2009

I got this vise from a friend recently. It’s very old but useful. I can really lay into it with a hammer and it doesn’t budge. It’s mounted on a heavy base with pedestal so I can move it around the shop. This is handy since my shop is so tiny. Does anyone know how [...]

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Electric bike battery box showcased and upgraded for cargo bike

December 15, 2009

The battery box needed an external charging connector and a way to lock it down. This makes it more convenient for recharging and more secure when parking at the store. I can leave the box locked to the bike and charge it up without having to take it all apart. This video shows me installing [...]

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Aligning the rear triangle redux

December 11, 2009

I think I now have a good solution for aligning the front and rear triangles for fitting the connections and for holding them in place while brazing. I thought I could get away from having an elaborate fixture for this project and I think I achieved that. I’m taking advantage of my welding table which [...]

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Finished the jigs to hold the dropouts

December 8, 2009

The jigs that will hold the front and rear dropouts are complete. I will use these to hold the frame in line to finish fitting the chain stays to the bottom bracket and brazing. Most of my time last week was learning how to use my new camera and edit video. I would rather work [...]

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Rear triangle complete

November 30, 2009

It took quite awhile but it is brazed and ready to fit to the front triangle. Fitting the tubes took a lot of time with my limited tools. It isn’t perfect but that is not the point of this exercise. I’m experimenting with this bike design to try and solve the weight distribution problems. I’m [...]

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Ten coats of paint!

November 25, 2009

While fitting the tubes and getting down to bare metal, I noticed that this bike has ten coats of paint; thick paint. It looks like tree rings. The finish is really nice with a lot of depth but I’m not sure it’s worth the extra weight. This project is moving along. I’m still fitting the [...]

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