How to build a e-bike

Building an e-bike from a push bike, an e-bike conversion kit, and an e-bike battery is a great DIY project. It allows you to create a customized e-bike at a fraction of the cost of buying a prebuilt one. Here’s a step-by-step guide to help you with the conversion process:

Materials and Tools Needed:

  1. Push bike (mountain bike, road bike, or hybrid)
  2. E-bike conversion kit (includes motor, controller, throttle, and wiring)
  3. E-bike battery (from PowercyclesAU)
  4. Battery mounting hardware
  5. Wrenches, screwdrivers, and tools for adjusting bike components
  6. Tire pump and tire levers
  7. Zip ties and cable management accessories
  8. Torque wrench (for motor and wheel installation)

Step-by-Step Guide:

1. Choose Your Push Bike

  • Make sure your bike has a solid frame and is in good condition, as you’ll be adding extra weight with the motor and battery. A mountain bike or hybrid bike works best due to their sturdy frame and ability to handle the extra load.

2. Select Your E-Bike Conversion Kit

  • E-bike conversion kits usually come with the motor (hub motor or mid-drive motor), controller, throttle, wiring, and a display (optional).
  • Motor: Choose between a hub motor (mounted on the wheel) or a mid-drive motor (mounted on the bike's bottom bracket). Hub motors are simpler to install, while mid-drive motors tend to offer better performance and are often quieter.
  • Make sure the motor is compatible with your wheel size and bike type.

3. Prepare the Bike for Conversion

  • Remove any unnecessary components (e.g., front wheel if you're installing a hub motor, or bottom bracket for a mid-drive).
  • Ensure the bike’s frame is clean and free from rust or damage.

4. Install the Motor

  • For Hub Motor:
    • If you have a hub motor, you’ll need to replace the rear wheel with the motorized wheel.
    • Uninstall the old wheel, and insert the motorized wheel into the bike frame. Tighten the axle nuts.
  • For Mid-Drive Motor:
    • For mid-drive motors, you’ll need to remove the bike's bottom bracket and install the motor in its place. This step is more involved, as you’ll need the correct tools to remove the bottom bracket and install the motor.
    • Make sure the motor is securely mounted and aligned with the bike’s crankset.

5. Install the Controller and Wiring

  • Mount the controller (usually located near the motor or in the rear triangle of the bike frame) and connect it to the motor.
  • Ensure all wires are routed properly and are not at risk of getting caught in the wheel or moving parts.
  • If your conversion kit includes a throttle, mount it on the handlebars.
  • Use zip ties to secure and tidy up the wiring.

6. Install the Throttle (Optional)

  • Most kits come with a thumb or twist throttle. Install the throttle on your handlebars in a comfortable position.
  • Connect the throttle to the controller via the provided wiring.

7. Install the Battery

  • Downtube Batter
    • Mount the battery securely to the bike frame. Many e-bike conversion kits come with battery mounting brackets or racks that allow you to attach the battery to the frame.
    • If your bike doesn’t have an integrated mounting system, you might need to get an additional battery holder or rack to ensure the battery stays in place.
    • Connect the battery to the motor/controller using the provided connectors. Make sure everything is connected correctly, and double-check the polarity before powering up.
  • Triangle Battery
    • Use the provided straps to secure the battery on to the frame!
    • Connect the battery to the motor/controller using the provided connectors. Make sure everything is connected correctly, and double-check the polarity before powering up.

8. Install the Pedal Assist System (PAS) (Optional)

  • If your kit includes a pedal assist system (PAS), you’ll need to install the sensor on your bike’s bottom bracket or crankset. This system detects when you are pedaling and provides motor assistance accordingly.
  • The PAS sensor usually comes with a magnet ring that attaches to the pedal crank, and the sensor itself is mounted near the bottom bracket.

9. Check Brake Compatibility

  • Ensure your brakes are functioning properly and that the motor doesn’t interfere with the brake system. Some conversion kits include brake sensors to cut off motor power when the brakes are applied.
  • If you're installing a powerful motor, it’s a good idea to upgrade your brakes to disc brakes or hydraulic brakes for added stopping power.

10. Testing and Calibration

  • Before riding, double-check all connections, and make sure everything is secure (wheels, motor, battery).
  • Power up the system and test the throttle and pedal assist to ensure they’re working.
  • If everything is functioning, test ride the bike at a low speed, gradually increasing speed to ensure everything works smoothly.

11. Adjustments

  • After your initial test ride, check if the bike requires any adjustments to the motor, throttle, or brakes.
  • Monitor the battery level, and make sure you’re not overloading the system.
  • Ensure that your motor and battery are compatible with the distance and speed you want to achieve. Larger batteries and more powerful motors typically allow for longer range and higher speeds.

Tips for a Successful Conversion:

  • Motor Placement: Hub motors are easier to install but tend to have lower efficiency compared to mid-drive motors. If you want better torque and performance, a mid-drive motor is recommended, though it’s more involved to install.
  • Battery Range: Larger batteries (e.g., 52v, 25ah, 29ah) provide more range and power, so consider your daily commute or distance needs.
  • Brakes: Upgrading to disc brakes or hydraulic brakes is essential if you're using a high-power motor to ensure you can safely stop.
  • Safety Gear: Always wear a helmet and follow local e-bike regulations, especially if your e-bike reaches higher speeds.

Final Considerations:

  • Make sure that the e-bike meets local laws regarding e-bike speeds and motor power.
  • Regularly maintain the motor and battery, ensuring all wiring is secure, and the system is clean and free of dirt or water damage.
  • If you encounter any issues, refer to the manual provided with your conversion kit for troubleshooting.

By following these steps, you can successfully convert a regular push bike into an e-bike. Enjoy the ride!