Build An Electric Motorcycle - DIY E-Moto From SCRATCH!

Build An Electric Motorcycle - DIY E-Moto From SCRATCH! Check out my blog for all the details on what parts and materials I used and how I put it all together:

In this video I show how I built a torquey electric motorcycle from scratch in my home workshop using basic tools. I built this bike for less than HALF the price of an equally sized ZERO S (~$5000 Canadian). This aggressive looking streetfighter uses the same 24 kW (32 hp) drivetrain as the previous Cyber Trike project. The QS direct drive motor produces 250 ft-lb of instant torque, 150 km/h top speed at 120V, and the entire bike only weighs 300 lbs, making it comparable to most 300cc ICE bikes.


Acceleration rate using mass (136kg) and force (250 lb-ft starting torque) = 8.17 m/2^2

0-60 time = 3.28 seconds:

For comparison, a Honda CBR 300r sport bike has 30.5 hp and weighs 364 lbs (165kg). Using the same resources we can calculate power to weight ratio = 0.082hp/lb. Acc rate = 3.439 m/s^2, and it's documented to do 0-60 in 7.8 sec.

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ROI breakdown:
Cost of build = ~$5000 total
Nominal battery capacity = 4.3 kWh
Life span of LiFePo4 cells = ~5000 cycles
Range per charge = ~80km @ 80% DOD (up to 100 km @ 100% DOD)
Grid energy cost per kWh to charge at home with 110VAC = $0.12/kWh
Cost per full charge (100 km 'tank') = 0.12 * 4.3 = $0.52
Cost per km for energy for electric bike = 0.52 / 100 = $0.005

Avg price of gasoline in Canada today = ~$1.50/ liter
Energy in 1L of gasoline = 8.9 kWh
Fuel economy of the most efficient petrol bikes = ~60 miles per gallon, or 25.5 km per liter
Cost per km for fuel for gas bike = 1.5 / 25.5 = $0.06

Electric bike energy cost savings per km = $0.06 - $0.005 = $0.055
Savings per charge/cycle (80 km) = $0.055 * 80 km = $4.40
Payback period based on full cycle charges = $5000 / $4.40 =
1136 cycles

OR
Savings per day based on driving an avg 40 km per day as a daily commuter = $4.40 / 2 = $2.20
Payback period = $5000 / $2.20 = 2272 days, or 6.2 years.

Ie: it will pay for itself in ~6 years (or 1136 cycles, more specifically), completely. LONG before the LFP battery wears out at 5000 cycles. At ~$200/kWh, I could replace the battery almost 6 times with the cost savings to be had - not that I would need to, though. I didn't factor in my time since I don't tend to keep track of it when I'm having fun, but a good fabricator should be able to build this in 2-3 weeks. At an avg wage of ~$20/hr in Canada, that translates to an extra ~$2K in labour. So technically, I guess it'll take 8-9 years to pay back the $7000 investment, which could be used to replace the battery around 7x in that time span, though it should only have gone through around 2000 of its total 5000 max cycle life span by then, so that's all $ back into my pocket, my friends (update - these calculations were based on set fuel prices before they skyrocketed so the results are relatively conservative, but should serve as a good example). 80% fuel eff vs 35%. Doesn't take rocket appliances :)

Specs:
Power: 12 kw/ 24 kWp, 32 hp gross
Motor: QS273 70H brushless hub motor
Battery: 74V/4.3 kWh LiFePo4
Range: up to 100 km's
Top speed: ~115 kph (71 mph) @ 72V, 150 kph (93 mph) @ 120V
Max torque: 350 Nm (258 ft-lb)
Controller: Kelly KLS72601
Wheelbase: 55" (140 cm)
Rake angle: 26°
Trail: 4.9" (124.5 mm)
Turning radius: 72" (183 cm)
Weight: 300 lb (136 kg)
Front suspension travel: 5" (130 mm)
Rear suspension travel: 8" (203 mm)
Front tire: 120/70-17 Shinko 705
Rear tire: 180/55-17 Metzler Karoo Street

Music: 'Dark Epic Hybrid Rock' by Pegasus Music Studio

[JamesBiggar]

Check out my new electric buggy that I just finished building:

Here are some answers to your most common questions about the bike:
#1 - "Why did you block the welding arc?" - Because flashing bright lights can trigger ocular migraines in people like myself which literally blind us temporarily, and can cause seizures for others. I can only weld for short periods at a time because of it. It has absolutely nothing to do with UV light or flash burn (which can not happen through a video).

#2 - "What's the top speed, acceleration time?" - I didn't fool around figuring these out on the road for what should be obvious legal, safety and liability reasons. These are better tested on a track, which I have no intention on renting because I personally don't care what the bike's limits are - I don't race professionally and I certainly won't be doing it on the street. But we can use well established math and science to figure it out for those of you who might be interested in building or converting a race machine to electric. Check out the video description for theoretical top speed and acceleration specs. You're more than welcome to build and test for yourself.

#3 - "What's the cost to build?" - See the video description. I broke down the cost and created a cost benefit analysis based on gas prices. Bare in mind the calculations were done prior to fuel prices doubling recently, so the savings to be had will be substantially more than what I've shown.


#5 - "Can a completely custom motorcycle be licensed?" - YES. Any custom personal vehicle can be licensed and insured for public road use as long as it meets safety and equipment standards for use in your state/province/country. Some folks seem to think it's impossible unless you're a manufacturer, but that couldn't be further from the truth. Here's a breakdown of how it works in my humble little province of New Brunswick:
Step 1: Know what you're doing. Building a custom vehicle is not a project for the avg DIY'er. You're going to need to acquire some skills and knowledge in automotive design and fabrication before jumping into something like this. I don't mean an engineering degree, but you'll need to at least spend a fair amount of time training with someone competent in automotive work. Like an apprenticeship. If you're not following a set of plans, then you'll need to dive deeper into things like chassis design and suspension geometry - it matters, a lot.
Step 2: Check with a local engineering consultant about the regulations and requirements for custom personal vehicles to be licensed in your area. Again, you can license your own ride, as long as it meets the requirements, which will differ with region. It would be wise to talk to your insurance company at this point, too.
Step 3: Build and test your ride. You'll need to play guinea pig. Take it for a ride in a parking lot. Check the brakes first, then performance, tune the suspension, etc. If you can, book a track for a day.
Step 4: When you're confident that you've done a good job, book an appt with a local engineer to have your ride inspected and tested on a brake and power dyno. If it passes, they'll certify it safe to be driven on public roads.

Step 5: Take said certification to the DMV to apply for a VIN# and acquire a license/registration. You'll need to prove that the vehicle is yours, so keep EVERY receipt for every part, nut and bolt that you buy and install. If you can't prove it belongs to you, then you won't get a title for it.
Step 6: Purchase insurance.
Step 7: enjoy your ride.

With this bike, you will save a significant amount of $ in the build compared to buying, but it WILL cost you more for the initial inspection (you only need an engineer to inspect it once), licensing and probably insurance too. So do your homework before jumping into it. But for most builders, the satisfaction of driving your own creation is well worth the $ spent. NO - crash testing is not a requirement for custom personal vehicles OR mass produced commercial vehicles anywhere in the developed world, contrary to popular belief. Manufacturers conduct crash test solely to further innovation and win safety awards that serve as bragging rights when marketing their products.

BOM:

4’x4’x1/8” (1220x1220x3mm) aluminum sheet
10 ft (152 cm) of 1”x3” (25x76 mm) 14 gauge rectangular steel tubing
12 ft (366 cm) of 1” (25 mm) diameter 11 gauge DOM round steel tubing
12” (31 cm) of 1 ½” (38 mm) diameter DOM round steel tubing
6” (152 mm) of 2 ½” (64 mm) diameter DOM round steel tubing
24”x24”x1/8” (62cm x 62cm x 3mm) steel plate
12”x12”x3/8” (31cm x 31cm x 10mm) steel plate
12”x12”x1/4” (31cm x 31cm x 6mm) steel plate
4ft x 4ft x ⅛” (122cm x 122cm x 3mm) aluminum plate
16 ft (5 m) of ¾”x3/4”x⅛” wall (19x19x3mm) square aluminum tubing
12”x3/4” (305x19 mm) stainless steel shafting or drill rod
Six ¾” (19mm) ID self lubricating bronze bushings
5-3602-a586-c0d73327934b


10”-11” (254-280 mm) ‘eye to eye’ rear shock absorber (consult local suspension specialist for appropriate spring
rate for your weight and unsprung hub motor weight)
14113355


Suzuki GSXR 750 front suspension w/ head tube bearings and race cups
ront+suspension&_sacat=0


Suzuki GSXR 750 front and rear brake calipers


Suzuki GSXR 750 front alloy wheel (be sure to match with same year/model as forks)
0


Left/right universal motorcycle brake levers
92613076939


Foot pegs/rests and kickstand

Clip-on handlebars
s/182681550392


10 yards of 1 meter wide 10 oz fiberglass cloth
RDS-LONG/312585593625?

2 gallons of polyester resin
7526952?

½ gallon of epoxy

2 gallons of RTV mold silicone
581798240


Liter of acetone (to clean up resin and epoxy)
882316


Liter of mineral spirits (to clean up silicone)
767964563


12kW/24kWp QS 273 70H hub motor

Kelly KLS72601 controller

288 6Ah LiFePo4 battery cells

72V, 40A LiFePo4 battery charger

100ft (30m) of 3mm^2 pure nickel strip

24S, 200A Daly BMS (LiFePo4)

10ft (3m) of 2 awg stranded copper battery cable



72V/600A contactor

72-12VDC voltage reducer
62572221


180/55-17 Metzler Karoo Street rear tire


120/70-17 Shinko 705 front tire

CT-22 Digital speedometer

Wuxing half twist throttle
96030

[auella]

This guy brought a whole new meaning to “fine, I’ll do it myself”

[hafeexius]

When someone makes an entire motorcycle from scratch and makes it look easy, you know you're watching a master at work.

Amazing build!

[DigitalGus]

I have all of the “raw” skills this guy has… I can weld, shape, electric…. And I am convinced it would take me 5 years to fabricate all these parts. Superstar. Subbed.

[soolenia]

Dude… this is extremely impressive with minimal equipment like yours! On a personal level it’s actually…… manageable!!

[solidkreate]

Just think guys, this is his first design. Just wait until he improves it even more. I wish him all the luck in the world and hope to see him develop and grow a company.

[StanoTheGr]

can we just appreciate that he shields our eyes when he welds

[alwinian]

Did we just witness 1 person building an entire bike start to finish. Mind = Blown. Insane build skills. Brilliant!

[civicprobe]

I consider myself talented in many areas, but you sir are ridiculous! Insane talent and skill to not just accomplish this but also make it look easy! Well done!

[jovanienazaire]

The only change I'd love to do is changing the location of the electric bike from your garage to mine. Awesome work!!

[RobertOw]

Hang on... that torque was limited to 16%, destroyed the road and nearly launched off the test pad in the garage? Sheesh! Man, this is a thing of perfection! Bravo sir, well done. You have my admiration. The design, attention to detail and engineering on display here is something to behold.

[docbroc]

This gives a whole new meaning for the phrase "Built not bought." Amazing work man.

[snew]

What an inspirational (and aspirational) project James! Thanks for taking the effort to share and thoroughly documenting your build... it's now on my build list :)

[CodeMonkeyG]

I came here trying to learn about converting my bike. This guy builds it from the ground up. Beast.

[diib]

This is without any doubt the best build i have ever seen!
I wouldn't hesitate to buy this bike!!!
I'm blown away
Great design!

[infographistehistorichaiti]

This guy can just step into his workshop and build a motorcycle. I can't imagine how awesome such skills are. It's incredible.

[swing-trading-karo]

As often as you watch this video, you get new information please share more videos like this you are great

[andrewpaulstancer]

Just did in his garage what took big manufacturers years to perfect ....And this is just a prototype... all the measurements and geometry.. Kudos to you Sir.. you are a true engineer !

[tongoltv]

You're like a one man army. You did all the modelling, electrical, mechanical, etc.. You're like a real life tony stark for cryin out loud. Mad skills indeed!

[johanrynjah]

The moment I saw you make your own bearing for the bike steerer/head tube I knew this video is gonna be a very interesting and rewarding one. ..Enjoyed every bit of it . ..