eBee gets made – Framebuilding 101 with Paul Brodie

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hi i'm paul brody this is my shop welcome we're 
talking about eb today last week we made a   center stand freebie i haven't finished 
it yet but it's it's basically done   what i want to talk about is how the bike 
got made and when it got made i started in   in 2012 it was always made for the nab show 
and as was 2013 probably march and so i was   under a deadline i worked on it basically 
every day for 90 days and this is the result   one thing when i look at electric bikes there's 
usually a lot of wiring so what i wanted to do   was to have eb as clean as possible so one of 
the ways i did that was to make a wiring tube   that's this gray tube here you see all the 
wires that feed in there there's wires cables   all sorts of stuff so this is clean and then 
they all exit here and go up to the handlebars   so i was pretty fussy about making the tube 
and on the first on the first version this   is the second version because it had to get 
restored we'll talk about that later i had a 5 8   tube and it was really hard to get all the 
wires in so when i had to redo the bike   this is three quarters so it's larger it was a 
lot easier to fit the tubes it fit all the cables   and the wires in there when i started making 
eb i had an idea in my mind but i didn't have   i had a concept in my mind let's put it 
that way but i didn't know exactly what   eb was going to look like so i made some 
sketches and i i came up with this shape   you'll see the sketches later when we 
do the slideshow and i made this first   i made i didn't know what it was going to 
look like so i made this out of mild steel   obviously the head tube's way too thin i wanted to 
know what it looked like and if i could weld it up   so this is mild steel and then 
i made it out of chromoly 4130   one of the hard things to do was to get 
everything in here it's called packaging because   there's a width to the motor you don't want this 
to be hugely wide because the pedals have to come   around so you can see here i've got some room 
but i don't have i don't have a huge amount of   room in there so i spent a lot of time figuring 
out how to get the bearings in there and all that   i got a jack shaft here too do you 
see how that works this is the motor and the motor spins and it goes down to this 
sprocket here this is the jack shaft because   the power has to go over to the right side at this 
point and then so the motor is powering the right   side sprocket and it's got a a sensor in the 
bottom bracket it's called a a thon it's a th o   n that's the bottom bracket there's a little wire 
that comes out that goes into the controller and   it senses how much power i put into the left 
crank it can't sense the right crank because   the right crank is is driven by the motor so hope 
that's all making sense to you the motor which   the output is on the left side ends up through 
the jack shaft it drives the chain on the right   and the left side is sensed when i started out i 
thought i was going to make a full suspension bike   that was the initial drawing all the sketch i 
made and once i started to work with all the   the motor the jack shaft the controller the 
battery the wiring all that i realized that   there's not really a lot of room and do i really 
need a full suspension electric bike for my use so   that's when it became a hard tail because it never 
used to have these lumps coming back on the i call   these the side plates i know some of the viewers 
are going to ask well what's it like to ride i've   ridden it a few times but there has always been 
a problem with the electrics with the computer   with maybe the controller i've had about four or 
five different issues and it never got resolved so   i'm sorry to say i don't actually ride the bike 
it's more like it sits here and it gets looked at   gets to go on youtube what happens when i ride 
it i have to push so hard to make the motor   work it's like i'm sprinting and i 
can only only do that for a short time   so the motor isn't isn't kicking in 
fast enough so i reset the computer   and then overnight it went back to the old setting 
so i'm back to where i started so one day maybe   i'll get that figured out but for now it's looking 
good here i wanted to use really nice components   on eb so on the back i got a roll off 14 speed 
and i also went for hope break so i got uh   i think i got a 180 on the back and a 203 on 
the front so it's got lots lots of braking   power there's no problem there eb is on battery 
number two i'll tell you a bit more about that   and i'll show you photos but eb was on fire and 
uh and the battery burnt all the wiring burnt   the tires went flat that's that's another story 
which we'll we'll get to so and so the battery   pack which sits right here it didn't used 
to be like that it was lithium iron and it   sat inside a carbon fiber shell here so this 
part is all new here all the electrics are new   eb sat apart for six years hanging up in 
boxes and then i got around to restoring eb   and and so the color changed as well it 
used to be red now it's um a maroon color   it was a custom mix i had two cans of paint 
and i mixed them together and i like the   i like the the shade so that's how it got painted   and a lot of the anodizing had to be redone 
as well because the fire and the flames really   really really did a number on the anodizing too 
on version one it was a a carbon fiber shell   it was it was two halves and i got the batteries 
in fine but it was so hard to get the wiring in   there so when i did version two i was much 
more conscious of leaving room for wiring there we go so i made got rocks in 
there and stuff i made this little   it's almost like a housing which gets on 
the side that's where this this plate goes   and that's the controller it's from 
grin technology and you can see all the   there's not a lot of extra room here and then i 
left the space in the back so that the wires can   come out nicely this is the battery pack and 
i got the charging port on the other side and   if you turn the wheel this just slides out so 
easy access eb's not a bike to ride in if the   roads are wet or are really kind of of damp and 
and dirty because i did that once and it took   a long time to clean there are so many little 
little pots and they're all kind of hidden away   very hard bike to clean that's one of the 
downsides but on on the flip side i think it   looks good so let's go do the slideshow here we 
are i guess i started earlier on than i thought   on on september 14 2012 and this is a sketch 
of what i thought eb might look like you can   see i've got a shock in there and it looks 
like it hinges at the bottom bracket and   this lump here i guess that would hide the motor 
and the controller and the battery and everything   so at this point that's what i thought i might 
do and then three days later i changed my mind   i still have the i got the rear suspension 
happening still but everything is a lot lower now   and i guess i'm thinking that i can put 
everything in here i don't think that   would work but that was my thought at the 
time i'm starting out i've got my sketch   i've got a catalog from a local company which is 
no longer in existence these pieces up here this   is just wood and what i'm trying to do is i've 
got a full scale drawing a little bit i can see   i can see a head tube here faintly it's in pencil 
there's a bottom bracket there and i guess i've   got an axle marked out there so that's the frame 
geometry now i'm trying to figure out what all the   trellis work looks like and it's a little bit of a 
take off on a ducati motorcycle they use a lot of   trellis frames and i kind of like that look so 
that was an influence i used but i did not copy   a ducati frame here's the motor i use it's 
called a stoke monkey motor and that's where   the free wheel goes on and then this is the axle 
the axle has to be held securely i'm doing some   more drawings here these these drawings down here 
this is the top view of those two side plates   and i'm figuring out how much space i need in 
between those those plates and to get the jack   shaft in there and all that it was there was a 
lot of head scratching going on at that point   what you're looking at here is the plate that 
holds the left side of the motor on this here is   a piece of stainless steel because you really have 
to anchor the motor there's a couple flats on the   on the axle and so if i make that out of aluminum 
i wasn't sure that it would be strong enough for   all the torque of the motor it's a it's 
a 700 watt motor so it's basically one   horsepower it's not like 50 horsepower but 
even so you want it to be mounted properly   so i've got a piece of aluminum here as usual 
i have no drawing i just have a piece of   paper or cardboard with all the lines and the 
mounting points on it i'm starting to work on   that on that engine mount on the motor mount right 
here so i'm starting to drill holes and i've got   the shape roughed out on the bandsaw here's the 
piece of stainless steel that i was talking about   i think i used stainless 304 and this is a boring 
barn i got the cutter and i moved the cutter along   that's how i made that shape there that fits 
this piece of stainless i'm trying to figure   out the sprockets and and the gearing obviously i 
had the frame made i don't have many photos of me   making the frame but you can see here that the 
frame is made that's the motor mount that goes   over here on top of this and out of that catalog 
i ordered some some sprockets this is just a basic   bicycle sprocket with some kind of a a bolt 
pattern in there and i don't actually end up   using it but it was good for mock-up and me 
figuring out what the bike's going to look   like and how it's going to work i'm starting to 
work on the side plates now so i had a lot of   one-quarter inch aluminum 6061 so i've cut 
out a shape and i'm making a hole now for   where the motor shafts are going to go through 
so this is the right side of the bike now and   you can see i'm still working as if this is where 
the swing arm is going to mount to down here   and it's another mock-up stage i went through 
lots of lots of mock-up used up lots of plate   i'm on the lathe now and this is this is the 
piece for the left side to hold the motor   and you can see here how i've had to hollow it 
out because that's where the chain in the sprocket   goes it was it was a bit of work to figure out 
how to get all the clearances and get the chain   in there and i think i used a 14 tooth freewheel 
off of bmx i think and that's what it looks like   so it's it's bolted on with three allen 
screws there i haven't countersunk them   yet and you can see how the how the chain comes 
out and also on the quarter inch plate i've also   milled that away so that the chain also goes into 
the plate this is what my workbench looked like a   lot in those days it was it was like that for 
days and weeks while i was trying to figure   out the plates you can see here i've got another 
plate over here i'm not using this plate anymore   and this plate here you can see how how the chain 
came out like that with this one here this plate   this is a different version now i've got that 
circular recess that's for the chain this is part   of my drawings i guess it's more like a a template 
and you can see here it says it's the swing arm   pivot so at this point i'm still thinking that 
i've got a shock absorber and a swing arm pivot   didn't work out like that i think i had to make 
another one of those mounts that went on the   on the left side i guess i figured out that the 
first one didn't quite work out like i wanted so   here am i machining a game i made a lot of chips 
and that is the final version you can see i've   recessed quite quite a bit out there's there's 
quite a bit of metal which got taken away this   is my sketch for the rear dropouts and i have some 
plate this was probably half inch or 5 8 i can't   remember now so i need to make this piece here 
out of the plate and then this piece here which   is the actual dropout it gets made out of aluminum 
i've got the plates and i'm starting to mill now   because i need to i need to relieve some areas so 
i've got a little small end mill there looks like   about a 3 8 10 mil i've got a right side i've got 
a left side and you can see the basic shape now in   the in the red felt pen and that's going to match 
my my cardboard template this is on my full scale   drawing this is the bottom bracket this is my 
tire there's the bridge tube this is the bend   of the chainstay and the chainstay i used i used 
i think it was pro well it is chrome molle and i   think it's three quarters of an inch and maybe 
a oh six five wall something like that so it's   it's pretty strong i'm still working on the on the 
side plates you can see i've got a different shape   here and um i wasn't happy with the shape of the 
plates for a long time i used up a lot of aluminum   i had i had a bunch and basically it all got used 
up this is more plates and i find i finally found   my shape i had in my mind i could see having the 
holes farther apart and then having it scooped out   having scoops around there lots of curves 
i like that more work on the plates this   is where the chain has to run like in 
the previous plates i'm finishing up   these these parts here so i did this on the 
on the rotary table that curve around there i   don't have a cnc everything is manual here you 
can see all the five different plates they're   actually numbered one two three four five 
and you can see the evolution i went through   from a real simple shape here to a much more more 
complex shape here but more pleasing to the eye   that's what i would say i had the shape of the 
plates and i had all the mounting holes made   and the holes for the axles and the jack shaft and 
now i wanted to make it look a little better so   i took masking tape and i i cut out circles that's 
what you're seeing there it's masking tape and i i   put it on where i thought the hole should be and 
then i i marked the middle with a red felt pen   you you can see the you can see the red felt pin 
there and then i i took it to the mill and what   these numbers are these are the x y coordinates so 
that i could use a center drill and do all of them   and then i wouldn't i could switch drills and 
i'd know exactly where my position is i wouldn't   have to relocate each time i just went to the xy 
that's the final of the two plates so each side   is is different the holes are in in different 
places for the lightning because of where where   the chain runs and things like that so it's uh 
that was quite an evolution to get to that stage   and my workbench still looks like a bit 
of a mess this is my chainstay jig here   this is what i use to build regular frames 
that's where the bottom bracket goes that's   the back axle i think what i've done is 
i've i've mocked up the rotor so i can   i'm not even sure what i used there a piece of 
cardboard or something but that's i just need   to know that i got enough space there so i'm i'm 
building the rear end now i've got a roll-off rear   hub this is a roll-off drop out that bolts right 
in so i didn't like the angle that it was holding   the rear caliper so this one here is the one that 
i made and you can see how i've changed the angle   this angle this is more of a lay down it's going 
to fit the lower seat stays much much better   i've got the rear end basically mocked up 
i've got the dropouts well no these are the   these are the plates that hold hold the dropouts 
and i've got them tic tacked in it's up on my   bench it's uh it's a mock-up stage seeing how 
the whole thing looks with the frame the engine   plates and the rear frame got the wheel in there 
at first i had much larger tires but didn't handle   very well at all they were they were hook worm 
tires i think a 2.5 didn't like how that handled   i got the dropout holders all all brazed in there 
and filed up that turned out nice it looking   pretty strong and chunky and that's what it looks 
like with the caliper mounted the rear wheel in   there i do not have the rotor yet at that point 
you can see how how the dropout slides back and   forth that's how you get your chain adjustment 
there's my wiring diagram that's how it's all   going to work i'm not an expert on wiring or 
diagrams or electric electricity so this is done   by justin at grim there's the cycle analyst right 
in the corner i needed to make the jack shaft so   having a piece of shaft which is i think it's a 
5 8 spore so i went to my local bearing supply   house and they sold me these two sprockets 
which is the right size for a bicycle chain   you can see how heavy they are they're just huge 
so the first step was to mount them on the lathe   this is the smallest sprocket i think and i'm i'm 
machining metal off and you can see the shine i've   got a carbide tool bit and there's a shine so it's 
pretty tough steel i i know the teeth are hardened   but the rest of it was pretty tough as well 
not as hard as the teeth a little bit of work   later there's my sprockets i've i've made 
them a lot narrower i've thinned them out   i've drilled holes and they've been they've 
been nickel plated electroless nickel plating   i needed to make a mount for the jack 
shaft so i found a piece of aluminum   you can see it's it's had a separate life earlier 
a previous life and so i'm just i'm just recycling   it rather than heading off to the metal shop 
and buying a brand new piece of aluminum   and that's what it looks like it holds the bearing 
in there and then there's three mounting holes   and it's got a shape to it this is the bottom 
bracket that i'm be i'll be using you can see   there's the wire that comes out because inside 
the bottom bracket is a sensor it's sensing how   much pressure i put on the left side i had to make 
a an offset middle ring so i had this old piece of   aluminum sitting in the back of my shop and it had 
been used for fixtures and all sorts of stuff and   it had if you look it's got holes all over the 
place but i found a spot right down here that   it didn't have any holes in it so i put it 
on the bandsaw and i cut it out and now i   had a piece of aluminum i think it was 
5 8 of an inch thick and this was a fun   a fun part of the build so now i've got it mounted 
on and out this is the arbor and then there's a   cap here an allen screw so i'm turning the od 
of the sprocket in my lathe it's thinned down   now and i've drilled some mounting holes and now 
i'm i'm drilling the no it looks like i got an end   mill there i'm milling out what will will be the 
sprocket i still have to shape those all the teeth   i kind of skipped ahead here this is the this 
is the big ring i'm making it's a 52 teeth and   i started out with a piece of 7075 i believe and 
once again i'm i'm milling the arcs for where the   where the chain goes but i have to do a separate 
a separate operation to get the shape of the teeth   so it's basically it's three different operations 
on a manual mill to get the shape of the teeth   and the sprockets basically made now you can 
see how the teeth are looking fine and i'm   i'm drilling all these big lightning holes in here 
that's what it looks like when it's all mounted up   and it's hard to see now i got the middle ring in 
behind it i think the next shot you'll see that   this is output off the motor that's the free 
wheel and then this is is the jack shaft and   there's a bearing on each side and then this 
chain comes down and drives the right side   that's a mock-up i've got the forks on it now 
i think they're marzoki forks and i use the   stand off another show bike it's made out of 
plexiglas and i'm pretty happy with how it's   turning out right now and that's just a detail 
showing a different view of the side plates and   how the rear part of the frame is bolted 
on i use eight millimeter allen screws for   these mounting points this is a piece of 
aluminum that i've i've started to shape   i've got a handlebar stem that i bought off ebay 
it's aluminum and i need to make a cap which has   a lower part that hangs down because i need to 
mount mount the fairings somehow here's the stem   this is the old cap and this is the new cap those 
are the holes i was talking about or the piece   that hangs down that's where the fairing is going 
to mount off that's what it looks like it needs to   be painted i put a hole in it to save some weight 
i rounded it a bit so that it matches the existing   stem somewhat and those are the two holes though 
those are five mil holes it'll take little allen   screws and i'll make a mount for that i got a 
piece of aluminum tubing here i've got the b logo   what i'm going to do is to make a b for the front 
i photocopied the b i made it larger i cut it out   i traced it with my red felt pen as per usual 
holding it in the middle of ice i've got a   quarter inch end mill and i'm making the shape 
of the bee i've got the shape mostly cut out and   then i do a little bit of filing a little bit of 
sanding and polishing send it out for anodizing   and while i was making things i thought i might as 
well make my own headset everyone else has a chris   king headset but i'm going to make my own so these 
are the pieces i think those are the two bearings   and i got the magnetized black and that's what it 
looks like you've got the headset and you've got   the b and this is the first color of red on the 
bike i painted it kind of a bright red italian   red you might say on the front of eb i knew that 
i wanted some kind of a little fairing i know that   most bicycles don't have a little fairing but this 
is an e-bike and there was going to be a computer   up on top so here's the handlebar you can see the 
bar there and this is the cycling com a computer   and i knew that if i had a fairing i could hide 
a bunch of wiring in here in between the computer   and the and the fairing and i was going 
to make the fairing out of carbon fiber   so how i do this i take aluminum welding rod 
this is 1 16 welding rod and you can bend it   really easy with your hands i've got a little bit 
of plate on the bottom which is mounted onto the   onto the stem mount that i made and i 
use a glue gun so all that's holding   this welding rod together is a glue gun so if 
you don't like the shape it's easy to change   now it's more filled in so i'm starting to see 
the shape much much better and i like the shape   that's that's the view from the inside 
that's the cycle analyst that's why i'm   going to see when i'm i'm riding the bike here's 
the mount offer that off of the handlebar stem i   took a couple pieces of tubing and i've got 
an insert in here that's got a five mil thread   so a five mil allen holds on these two and then 
there's a cross piece across there and that mounts   on the fairing and the cycle analyst over 
the over the welding rod i put masking tape   and then i fiberglass over top of that so now i 
have a hard shape it's a bit of work and now i   have to add some order body filler and smooth it 
all out in fiberglass work i'm working with carbon   fiber basically you have to make the shape that's 
known as the plug and then you make the mold so   i've made the plug it's all painted and waxed 
and this is the gel coat that i've sprayed on   and then i can add fiberglass on top of that 
this is this becomes the mold so it's the plug   the mold the part it's kind of three piece three 
piece operation this is the mold i've tried to   take out the plug and i've had problems the the 
plug is stuck inside the mold you can see some of   the pieces here but i have a problem now because 
if i'm not careful i won't have a mold or a plug   but i got all i i worked really carefully and 
i got out the plug and i was left with the mold   and there's my part this is i've got light 
reflecting off so ignore that this is my my   carbon fiber fairing this is this all has to 
be cut off this is the excess that was outside   of the mold so i'll cut all that off and then 
that's the final product i even had decals made   that were on a curve i got the deco mater maker 
to pull it down so that when i put it on there   on a curved surface it became level now i got 
to make the battery box so i knew what size i   wanted so i took some plates and i i machined up 
a couple dowels with threads in them and that's   that was how high they were going to be 
and these these plates on the other side   that is the shape and those would those two halves 
would come together because i needed a left and   a right i took some plywood and i i built it up 
and i'm almost at the height not quite a little   bit of bondo a little bit of sanding you can see 
how this this one on the right has its shape more   defined than the one on the left because i need 
to do a bit more sanding there this is where the   battery is going to hang so this is version one of 
eb and you can see i've got the batteries inside   these wires here coming down that's the outside 
shape that i'm looking for i've done a bunch of   sanding so this is the basic shape that i want now 
i have to paint them so that when i make the molds   these these plugs won't stick inside the 
molds that's the plugs they're all waxed up   they're all painted they're very shiny there's 
no imperfections in there so i'm ready to wax   that and to spray on the on the gel coat and make 
the actual mold now that's the molds i've put the   fiberglass layers over top it's about a quarter 
inch thick those are the molds they're all they're   all mounted on boards i've cut the tops off i 
need to wax them and then make the pieces make   the two halves here's the carbon fiber cloth that 
i'm using it's not it's not pre-preg i don't use   an oven and autoclave and vacuum bagging 
and all that this is just laying up like   fiberglass but it's fine for what i want to do 
i've started to lay up you can see how i've got   i got the fiberglass cloth in there i 
can't do it all in one piece because   because the bend is too sharp i need to put 
pieces around the side as well it's a little bit   of an art learning how to do all that those are 
the pieces they're all made now you can see how   how the fiberglass it sticks up and you 
have to use a brush and a roller to get   all the air bubbles out if you're not 
careful you can make a piece which is   is strong but it won't look very good because 
you've got air bubbles and things like that   so they work pretty well but i didn't leave enough 
room for the wiring the batteries went in there   fine but the wiring there was so much wiring 
and you couldn't really shorten up the cords   because it'd be too much work with all the ends 
on them that's the finished product it hangs down   that there is the mount and then this is see 
all this that's all the wires that are going   in and out because i got the controller inside 
there as well there was not enough space i   should have made this a little bit bigger but 
anyway something happened with the batteries and   i guess that story is coming up right about now 
i used eb for one ride and it wasn't going real   well because the motor was cutting in and out 
and by the time i got home i was basically i   wasn't getting any help from the motor so 
that was my first ride on eb so eb sat for   quite a while maybe a few months and then i was 
teaching frame building 101 out at the university   so i thought oh i'm going to take eb out and 
i'll charge up the battery out there so i'll   get the bike out there and it's a 52 volt system 
and i didn't know at that point that if the if   the volts go below half that then something 
is wrong with the battery and you should not   ever charge it up when i started charging up the 
battery it was at 13 volts and that's always going   to be a mystery of how it went from 52 volts 
down to 13 because i know i never left it on   so i'm charging the battery and it's been on 
charge for a few hours we're outside having   lunch and then suddenly inside the aircraft 
hangar which is where the class was there was   a huge commotion and the aerospace students are 
running around they got fire extinguishers so   i went running inside and eb was on fire and 
there was an orange flame and it was literally   three feet wide and three feet high level on top   and it took three fire extinguishers to extinguish 
eb because once as soon as the fire went out   it started right up again and it was kind of a sad 
day because eb had had burnt and all the cables   melted both tires were flat lots of smoke damage 
and the fire extinguisher that doesn't help at all   so basically eb sat for about six years sat on 
a shelf and then i decided i would restore eb   so i did and i got all new electrics i'd like to 
thank you for watching our videos i hope you've   enjoyed watching eb in the construction phases 
many years ago if you would like to support us   there's a couple links on your phone if you look 
for the arrow on your computer it says show more   if you click on those you'll find the links below 
you can buy us coffee you can like you can support   us by buying shirts hoodies things like that 
thank you very much take care see you next week you

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