Custom Built e-Trike

I started building up a custom upright delta trike frame some months ago after alot of research, I have the worklog on Endless Sphere forum thought i would pop it up here also might be of interest to some. (FYI..the below trike build is actually the 3rd frame the first two have been scrapped due to weight issues...)

Lil breif...I am building the trike for local use, i live in an EXTREMELY hilly area of Perth Western Australia and am classified as an incomplete paraplegic hence the need for 3 wheels...the trike will require to be able to travel ~15km on a charge YES charge it will be powered by a 1000watt 48v 20ah setup ..why? its HEAP more powerful than the 49cc 2 strokes has oodles more torque is capable of producing higher top speeds doesn't stink is cheaper to run its silent, i will also be legally able to ride on cycleways in OZ and seeing i have no need to cover over 15km it suits my needs to a tee...

I shall simply transfer this frame build directly from ES forum in its entirety to save re-writing what I have already done...

Worklog for 3rd trike frame begins....

My brother dropped by yesterday witha a couple of 'donor' bikes for me i am thinking of knocking up a quick frame out of possibly for a small 49cc 4 stroke ICE engine (my brother has the 2 stroke variety, goes well but is noisy and smelly) Obviously this idea (puting in an ICE was dismissed this build WILL be electric)



me+5inch angle grinder+mig+ 2 hours=


(obviously the pink "additions" will be made in steel and added for strength etc...

I like the look another 2 hours tomorrow ill have usable frame i can bolt a trike conversion rear end too pack with batteries and/or lCE motor hehe FYI the frame in pic is lighter than MarkII chopper style frame im currently working on ;-| The frame is ~20cm longer stretch than stock, hmmz 10-15 degrees increase rake (plan to add rake to forks to bring it to ~30-40 degree rake) and have reduced the height by ~10cm on stock mountain bike frame i would guess soz lil late and JB Black & pizza time so no "exact" measurements shall get those by days end tomorrow....what will i do with it ::shrugs:: not sure... just knew it would be a breeze to cut and re-weld a couple frames tubes line up easy and the rear end is made...just a lil break from the full custom frame... will finish welding it up tomorrow before continuing on the markII 'chopper style frame ;-)

Well i been forced out of my workshop for a few hours as the exterminator is spraying so i thought i would take a quick pic to post.



I fully welded the frame this morning, still need to make some custom shock mounts i wont be using the originals along with some bracing brackets for the bottom and front tube connection.

The bike measures 1870mm from front of tire to back of tire (thats ~6 foot 2-3? in the outdated money)

I decided in place of a bracket to reinforce the front down tube i would add an additional 'upright tube' (look closely also includes mounting points for drink...erm stubby holder ;-P well i need a place for my "roadie" I am an Aussie after all and we needz our beer like you Americans need war and the imperial system :-P) this not only reinforces the front joint but the rear 'pivot' that i joined to the lower 'parallel' tube



Im happy with the look and i'm more comfortable my test rider (Flavio) will come out of the incredibly steep downhill high speed test run alive and in one piece hehehe (the objective is to obliterate 'safes' top speed even if i dont fit the motor and doing so without being hunched over like a dog takin a crap :-P) ... As can be seen i also gave the trike conversion some "love" so as it fits neatly. I also spent a few hours cleaning up the welds today, Matt (1000 watt) (THE same '1000watt' from this forum, as some may have already seen he is INCREDIABLY skilled fella and a TOP bloke to boot who has helped me immensely, was alsofirst to suggest meeting up for a chat when i joined ES forum ( we have caught up on countless occasions now excellent having someone with similar interests to chat to IRL [in real life] hehehe) has found a place that will powder coat the frames including powder coat undercoat for $au55 so welds must be neat ;-)

I want to finish the drive train off tomorrow, this will include fabricating motor mount and fitting the drive gear for the motor to front crank/sprocket...

More tomorrow ladies ;-)

p.s My local bike shop has agreed to lace up my trike hubs into 20in rims for 35 a pop so shall drop them off tomorrow ;-)

I do now as you know and am VERY much looking forward to the fabrication process Doc...Those that haven't seen Docs latest mosey over here and checkout another use for snow skis.. ::wink::

LiL Update on my build....

A seemingly "easy" straight forward piece to make...a motor mount...well, has taken up all day to do..shall let the pics show what was done as i have a few mates
here knocking back some JBs and don't wan't to be completely unsociable (note* i have not got the correct bolts to mount motor in newly fabricated motor mount, hence the ventilation holes may not seem "lined" up i can assure you they will be when correct size bolts are used ;-) Obviously there is still some welding to do buuuut mates arrived and was 'bourbon o'clock' so....



Small step closer more soon...


Update


For the last week there has been a BIG clean-up at my place due to our first council curbside rubbish collection in over 12 months happening this week...This
has slowed progress on my trike BUT also bought to me a few new "options" in terms of front shock choices thanks to locals 'trash' being my 'treasure' (ie. me and my mate have taken a handful of drives in the Ute around the area scabbing up bikes and parts off the side of the road)... Along with a couple more shocks a friend has found in his garage left over from his fathers bike shop owning days that i would LOVE to use but alas they have no disk brake mounts on them...heres some pics-->



I finished the rear shock mounting today and tacked it in place before mocking up the trike to assure ride height was correct prior to me welding the mount in place.
I'm happy with the height, now i will work on mounting the seat, i shall be utilizing a set of non-suspension forks legs mounted upside down & parallel for the seat to sit on...curious? shall see this next update... I will also be able to workout the 'platforms' that will hang from the frame for my feet to sitz on once i have the seat on her. DEFINITELY heading to local bike shop tomorrow with the 20in rims and trike hubs to have them laced up also ;-)

I can still lift the frame with forks and wheel mounted!!! SO much lighter than originals...

Toodles from me for now ;-)

Kim

***that brings MotorBicycling forum up to date shall continue updating as I progress through with the build...

uhm..few details probably not mentioned in this section of the veeeeery long worklog (which contains the other 2 frames that were constructed etc etc etc)so please freel free to ask any questions that you may have happy to answer them if they arent already covered :-)

I have enjoyed reading through THIS forum the last 3-4days checking out everyone's builds some VERY talented individuals here (pitty more havent realized how much better the electric technology can be though. : hehe :-P ) I look forward to continued participation here ;-)

Regards

Kim

Wow Kim that bike sure looks awesome. I'm sure it's going to look super sweet when it's topped off with some killer paint. I can't wait to see this baby finished out.

Thanks mate...hope so, shall definitely put some hours in prepping it for paint so it will get a decent finish :-) I have my own spray gun and compressor and have done a fair whack of painting so i'm confident the paint at least will look reasonable :-)


Update

I got a good start on the seat pan 'frame' today...as mentioned in yesterdays post i have used the legs off a set of forks...actually, i have used two sets, the support brackets are the bends from a second set of forks ;-) Still much work needed though, hope to finish them tomorrow, i have splashed some anti rust primer on anywayz, its getting very cold here at night and im finding the frame is damp in the morning, not so good on bar metal and welds...



FYI: for those wondering why i dont simply use a 'standard' bicycle seat, i have broken my pelvis in 16 places and it didnt go back together the way it was 'made' hahaa so i am unable to sit comfortably on a 'standard' seat it has to be alot wider and flat...

Back with update tomorrow...

Kim

Nice work, looking good Thanks for the pics

very cool build !!!
you do nice work

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Bill (aka azbill, aka azkronic)

yesterday is history,
tomorrow is a mystery,
but today is a gift...
that's why it's called "the PRESENT"

Cheers fellas :-)


Update


Well fellas I finally got my rims/hubs laced by local bike shop (dropped them off a week ago today ;-| ) I really wanted to
get these done so i could get on the bike to determine the 'correct' seating potion AND the placement for the yet to be fabricated platforms for ma feetz to sit on...
As is the seat needs to be relocated ~100mm further back this will aso allow for the platforms to come back more also (away from the front wheel)..



My 'test rider' Flavio... is sitting on the bike Flav is 180cm hieght hope this gives you all a better idea of the size etc...not so 'safe like' now is it Doc hehehe

Will move seat back tomorrow/over weekend as well as getting a start on the tube work for the platforms ...

OH..i also 'prettied' up the drive sprocket and lightened it up a lil as well as making 5 spacers 9.5mm in height grrrr took me 4 hours to finish all this ::sigh::

Ciao for now fellas cheers for the continued interest :-)

Kim

EDIT: NOT the handlebars and forks that will be used in final assembly...i need to change the head tube on the frame in order to fit the forks i will be using, they are of the threadless variety and as yet i have no idea what size tube is required OR where i will source one...well that's not entirely correct, 're-sizing' a tube to fit a threadless headset wont be an issue, i just need to get the headset first...

That is looking sweet! I am not much of a trike guy but that is one trike I would love to ride. You've got some mad fab skills

Thanks mate... tiz getting there slowly, everything seems to take so damn long, the smallest of things that you would think are a 5-10 minute job quickly turn into hours :: sigh :: I shouldn't whinge makes me sound English :-P LoL..it gives me something to do and it is enjoyable getting out in the workshop anywayz ;-) I myself wouldn't own a trike given the "choice" not a big fan of them myself TBH unfortunately my physical situation dictates what i can and can't do...two wheelers unfortunately are in the 'can't ' bracket so I thought i would have a crack at building a semi-cool looking semi-legal trike :-)

Thanks again for your interest buddy hope to be back with another update in the next couple days :-)

Kim

NICE!!!
Can't wait to see it finished.
Pure Genius.

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You have found the fountain of youth. Ride and forever stay young.