Full Build, No Talking: Vintage Honda Motorcycle Conversion to Electric.

1967 Honda "Baby Dream" CA160 converted to electric/EV. QS hub motor, Kelly motor speed controller, LG Chem pouch cells.

Specs:
- 1.4kwh battery, 4kw motor (6kw peak), 72v system
- top speed: 55 mph (88 kph)
- range: 20 to 25 miles (32 to 40 km)
- charge time: 2.5 hours (6 amp/432 watt charger)

EV Components:

40 used LG Chem pouch cells from Batteryhookup
15ah 3.6v LG Chem pouch cells (when new)
200mm x 260mm x 8mm - or - 8” x 10.5” x 3/8” (with the plastic cases)
need to cut these 4p modules to two 2p packs:
20s2p = 72v 30ah and 90amp continuous discharge rate (3c)
but if 2/3 capacity left, then only ***20ah and 60amp discharge rate***
40 cells total, a four pack is $20, that’s $200 total
max voltage: 84v
min voltage: 50v
peak discharge current: 150amps ???
6.5kw ~= 72v x 90 amps (continuous discharge rate)
4.32kw = 72v x 60 amps (continuous discharge rate @ 2/3 capacity)
....
motor:
maximum motor current at 72v: 90 amps = 6.4kw
continuous motor current at 72v: 55 amps = 4kw
...
controller
Kelly KLS7245N
90 amp continuous and 270 amp peak (phase current, which approaches battery current as RPM approaches max speed)
...
DC-DC converter:
20w from amazon
BMS:
DALY 100amp 20s 72v
Contactor:
display: 72v charge meter from Kelly
Connectors and misc:

The loss of the aesthetic element of an engine has left many E-moto builders struggling to find ways to keep their bikes visually appealing. Too often has the engine been replaced by a blocky battery enclosure the size and shape of a Gateway 2000 PC.

But that was not the case for my latest project: a 1967 Honda CA160 converted to electric. The removal of the engine actually makes it look better as it lets that beautifully sculpted frame become the focal point. The curvaceous shape of the fenders, the square front-end assembly, and the angular, sharp lines of the stamped-steel frame are now fully on display.

One night I was showing my wife a picture of a Yamaha XS650 and a red Honda CA160, and I asked her which one she liked best. She said the Honda, but only if it was black. That night I woke up in my sleep and started looking at Craigslist for no particular reason. And then I found it! A black Honda CA160. I bought it the very next day for $500.

The engine was seized. Its the typical story: the seller's neighbor's brother left the plugs off after it lost spark and he couldn't fix it, and there it sat for over 10 years in the back of a barn. So with a seized engine, sculpted sheet metal, and a stamped frame good for hiding wires, this was the perfect bike for an EV conversion.

But I had another reason to convert it to electric. I wanted my wife to be able to ride a motorcycle along side me, but she doesn't know how or want to learn how to use a manual transmission. She is also really sensitive to the smell of gasoline and exhaust fumes, and she hates loud motorcycles with a burning passion. So this electric bike is perfect for her.

Riding it just puts a smile on my face, it's a very pleasant experience.

It's also much faster and quicker than my 200cc bike, but without any of the drama. You just hit the throttle and you're suddenly faster than traffic and there was no quake from the engine and roar from the exhaust. So the thrill is very different than that of a conventional bike with a gas engine.

And for that reason, the bike doesn’t appeal to everyone. Let’s just say the readers of Motorcycle Classics don’t have a lot of nice things to say about this bike. Yet the overall response has been very positive. My favorite is when someone sees it, someone who knows nothing about motorcycles, and they just look at it and see a nicely restored but otherwise normal, classic motorcycle. They don't even realize that it doesn't have a gasoline engine.

Song credits:

Crushin, by Audionautix
The Red Blouse, by The Matt Villinger Trio
Guitar Elation (can't remember the name of the song)
What a Wonderful World, by yours truly on a Wurlitzer electric piano

0:00 Disassembly
4:22 Unboxing
6:18 Battery pack
8:44 Swing Arm
9:44 Paint
10:48 Assembly
14:00 Seat frame
16:21 Battery enclosure
20:40 Wiring
24:41 Riding

[bill]

Phenomenal build, EV conversion, and most of all, video. The stop motion, editing, planning, is insane. Most people would not realize this unless they tried to make a similar video. This is pro level stuff here!

[the_interim]

The dedication put into filming this with the stop motions and all... Mad respect.

[Adrian_Nel]

Anybody who has the patience to restore a 56 year old bike has my respect. Anybody who is prepared to add the work of stop gap videography on top of that is too much for my brain to comprehend. So is the battery enclosure. Art, I'm telling you, it's feckin art!

[pandaexpresso]

You are one of the first (that I've seen) to have put so much artistic flair into an electric conversion. Major badass points on the controller heatsink and placement!!! Big smiles on the ending music pairing.

[EV-olution]

I have never seen anyone on YouTube put this much effort into production and video editing to make this type of "stop motion" effect for a topic that has nothing to do with animation. This is just phenominal and my hat is off to you because the amount of work to get this effect must be enormous, on top of actually restoring and converting the motorcycle!

[fattyfat-fat]

In 1964 i was 15. 5 and got a learner's a Honda Dream 150. Now i'm 75 and still ride, but on Triumphs. The Dream was my first love, however. i still dream about finding and restoring one. Glad to see that you did. They were extraordinarily beautiful classics that have never bean bested for good looks. 😊

[himsayhimdo]

Beautiful build video from beginning till end. Love how you blended the battery pack with the lines of the bike. Superb build.

[chetleonard]

cable ties to get the tire on idea is great! I'll try that next time

[ejakeway]

The effort to time lapse this alone deserves all the praise I can give!

[tomreingold]

I want to echo all the compliments everyone else has offered. I'm a bicycle person, not a motorcycle person, but the worlds overlap, and I can appreciate what you've done. Now, speaking as a bicycle mechanic and wheel builder, I couldn't help noticing that the rear wheel's spokes are in a radial pattern rather than crossed. In my world, that's a guaranty that the spokes will fail from fatigue because of the torque coming from the hub. I imagine in a motorcycle world, that problem will be magnified. Do others have experience with a wheel like this, laced radially?

[adipurnama_workshop]

This is crazy!! Build it self is not easy, making stop motion animation during build it another story. Thumbs up!

[wally]

I had the 1966 Scrambler 160 which was my first bike back in high school. Fun but the suspension was super bad and I think I am still paying for it today. I actually broke both feet pegs during a small jump. I like the time lapse no hands video.

[SixPackDan]

I love this whole project but the seat and rack are just the bomb! I used to own one exactly like this. Still miss it.

[REDPUMPERNICKEL]

Had a bike back in '67
looked very much like that one,
blue CD175 it was
met the nicest people
freed me from virginity prison

gas was maybe 50 cents a fill
and could drive non stop Ottawa to Barrie with
60 miles still sloshing in the tank

but what I really wanted to say was
kudos on the conversion and the filming
finding parts, sheet metal arghh, editing
totally awesome!

[wukerplank]

Man, this video is a work of art in itself. The bike conversion is another one. Two impressive results in one video 🤩

[MrKrinkly]

Back in 1971, at the age of 16, I bought a 1965 CA-160 305 Dream from a buddy. I rode it daily for 3 years and sold it for the same $150 I had given to buy it! I think about that old bike to this day, and if I still had it, I would absolutely do just what you did to this '67... a beautiful bike to start with, and a beautiful conversion on your part! Glad I watched the vid, and many happy and safe miles of cruising to you.

[ProtocoleSigma]

Rarely commenting, but this is definitely worth typing. Awesome build and video! 🎉

[vaidyanathanb]

WONDERFUL !!! With the Fossil fuel prices skyrocketing, I feel this is a good video for people (if interested) can try this out on their motorcycles. I am planning to do this and convert my motorcycle to a Hybrid model (Petrol + Battery). EV drive to the front wheel to use it for city and congested traffic circumstances. Thank you for such a wonderful video

[zenzen]

I had an old black 1987 Yamaha Virago 535 that I was thinking of doing something like this but I got rid of it during my last house move ! Oh man I'd wish I'd seen this video before I sold it for almost nothing. Your conversion is top class. The battery box shape is exactly in keeping with the original design. Well done. So many other conversions just have a huge square box to hold the batteries. Totally awesome work !

[carlhenrikk]

Dude! Even the dents are straightened in stop motion??? I am shocked by the amount of time and artistry that has gone into this video. Most insane restoration video I've ever seen...