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Building a Bike E Recumbent Hybrid
Project started June 17th, 2008. Check back to follow progress and results.
ENOUGH ALREADY! O.K. June 13th, 2008 I pulled up to the pump. Yes, its gone up another dime since last Friday but I've really got no choice. So, I get out of my 2003 Ford Expedition, (16 miles per gallon Hwy.), unscrew the cap and bend over, $97.00 to fill it up. Somethings got to give. Now I've been riding bicycles since 1992, mainly recumbents just for the fun of it. Over the last few months, I've started riding my bike to work a few days each month. I live about 6 miles from work in Cullman, Alabama so the round trip is about 12 miles. I enjoy riding but some days you just don't feel like riding. I've been researching, over the past few months, the idea of an electric bike. So here is my story of taking my BikeE and eletrifying it. I've had the BikeE for several years, found it on Ebay for $800.00. You can do this project with any bike you have, or you can pick up a used bike for almost nothing. I will tell you that if you've never ridden a recumbent bike, you need too. Once you do, you will never pedal an upright again. You can find the components to do this project all over the internet. It did help me to read stories from people that had done it before. Youtube.com is a great resource. You'll find videos and step by step instructions. Listed below are the resouces I ended up using and how it all worked out. |
The Power Ride Store in Atlanta
My kit did not come with bag or batteries. The Power Ride Store in Atlanta, Georgia is a great resource. I got the last Crystalyte 404 front electric hub kit he had in stock. Earl didn't have the batteries or charger instock, he does usually have them, but helped me understand exactly what I was looking for and pointed me in the right direction. I ordered the following on Tuesday, June 17th 2008 and recieved it all on Wednesday, June 18th 2008. Cystalyte Model 404 Front Hub Motor: $290.00 I upgraded to the 40A 48 Volt Controller: $230.00 Throttle Thumb control: $22.00 E-Brakes: $20.00 Battery Cable: $7.50 Key Switch with Wiring Harness: $18.00 Shipping/Tax: $16.99 Total: $604.49
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EVDeals.com is, after much research, where I ended up getting my batteries and charger. I emailed Scott at EVDeals on Tuesday, June 17th 2008 and explained to him what I was looking for. Wednesday Morning I got an email back from Scott with recommendations. I called him and placed the order for the following on Wednesday, June 18th 2008. I recieved my shipment on Friday, June 20th, 2008. (4) 12 Volt, 12Ahr BB Batteries: $195.00 (1) Soneil 4804 48 Volt Chager: $99.95 Shipping/Tax: $26.98 Total: $321.48 |
Total Cost: $925.97 Total Time: about 4 hours Beginning weight of bike: 41 pounds Ending weight of bike: 102 pounds |
Wednesday, June 18th 2008: My kit arrives from The Power Store in Atlanta. I rushed home like a kid at Christmas to start work on it. First step was removing my old rim from my bike. I took my tire off the old rim and installed it along with a new tube on the Crystalyte rim. I get most of my regular bike supplies at Werner's Trading Company in Cullman. Justin is the bike Guru there and can help with just about anything. No problems. I installed the rim on the bike. I did have to adjust the front brakes a little. Installed the thumb throttle by sliding the right handle bar grip, 7 speed shifter and rear brake handle off the handle bar. Slid the thumb throttle right on, then the brake, then the shifter and finally the grip. No problems. Total time today about 1 hour. Thrusday, June 19th, 2008: O.K. now on to the wiring. No wiring diagram came with the kit but I did find an Installation Guide on the web. Installed the controller on the tail end of my BikeE and ran all the wiring down the frame. I used some little adhesive cable clips and some zip ties from Radio Shack. The only real problem I have is the throttle cable from the handle bars to the controller really needed to be another two feet long. Made it work but I may end up moving the controller in front of the seat instead of the tail end of the bike. Now I'm just waiting on the batteries and charger. Total time about 2 hours. Friday, June20th, 2008: I recieved my batteries today. I got home and started working. I did move my controller from the tail of the bike to just in front of the seat. That gave me enough throttle cable to route it securely. Hooked my batteries up in a series and checked my fuse. Oh no....they sent me a 20A fuse for this 40A system...its gonna blow. Hooked it all up and like magic...IT WORKS! Yes, I know I don't have my charger yet and yes I know the fuse is gonna blow but I got to try it out. I'll take it easy. My Wife is really amused with all my excitement. She thinks I'm a nut! Wow, this thing moves. You can hear the front wheel digging into the pavement as I shoot up the hill in front of my house. I make it about 1/8 mile and...yes...you guessed it...the fuse blew. I had some friends coming by the house so they brought me some 40A fuses and I'm back in business. I'll not ride it anymore though until I get my charger. I put the bike up off the floor and hit the throttle. My bike computer reads that the front wheel is spinning at a rate of 33 MPH. Total time about 1 hour. Monday, June 23rd, 2008: This morning I had to fill up the tank again, $100.00 to fill up my Ford Expedition. If you remember, I just put in $97.00 (10) days ago. I got my batteries today. I took the bike out for a real ride. I covered about eight miles. Man, this thing flys. Got back home to hook up the charger and we have a problem. There is a short in the connector from the charger to the batteries. I take it apart and one of the wires has come loose. I break out the tools and fix the loose wire. The charge indicator is not the right color to be charging but we'll see what happens. Wife is still rolling her eyes at me. Tuesday, June 24th, 2008: I got up and rode the bike to work today. The charger is just not charging so I bought a couple of single 12 volt chargers at Wal-Mart to get me by. I have a replacement 48 volt charger coming. The round trip was 15 miles. I had to take some movies back to the video store. I averaged 19.1 MPH including the city stop and go driving. I still haven't really opened it up, taking it easy until I get use to this thing. In town I can actually keep up with the traffic flow and even accelerate faster than all the poor folks around me. Yes, she is still laughing. Wednesday, June 25th, 2008: I'm thrilled with this bike. Rode it to work today. I made it to work in 12 minutes and 29 seconds. Usually takes me about 10 minutes in the gas hog. Round trip was 12.2 miles and I averaged 23.8 MPH. Top speed was about 33 MPH. Friday, June 27th, 2008: Out for a joy ride today after work. I rode 13.5 miles and averaged 23 MPH. I got my replacement charger today, plugged it in and this one works great. Wednesday, July 2nd, 2008: I am so happy with the performance of this bike. I've ridden it to work for the last five days. Averaging a 13 mile round trip with an average speed of 22 MPH. You could not ask for any better acceleration. Once you are up and going the bike will maintain 20 MPH on the flats easily without pedaling. I pedal all the time so I'm doing about 24 MPH on the flats, 33 MPH down the hills and about 20 MPH climbing moderate hills. I'm tracking what this bike is saving me in driving expenses. So far it looks like it is saving me about $6.00 per day. Plus, I get great exercise for 15 minutes, two times per day and ITS FUN! Photos below |
You can contact me if you have questions.