Building an Ebike (Nitro)

Ebikes come in various shapes, sizes, and forms, each distinguished by the bike frame and motor used. Drawing inspiration from my love for mountain biking, I opted for a mountain bike frame for my ebike conversion. Choosing a geared hub drive motor, specifically for recreational use and long lifespan, added another dimension to my project. Now equipped with a full design and motor system plan, I proceeded to order the necessary parts.

Mounting the Motor:

Converting a Hiland mountain bike (26-inch tires, disc brakes, and an 18.5-inch frame) involved replacing the regular wheel with the hub drive motor. This required relocating the disc brakes, adjusting the rear drivetrain, and swapping out the tube and tire. Securing the wider ebike hub motor within the frame presented challenges, eventually resolved by careful positioning and the addition of a crucial component: the torque arm. This safety measure prevents the wheel from dislodging at high speeds, especially critical with a powerful 48V 1000W motor.

Brakes:

For brakes, I opted to use the regular disc brakes without a power cut. Aligning them with the new rear wheel rim demanded precision due to the significant differences in tolerances between a hub motor rim and a regular rim.

Wiring:

In managing the wiring, I employed a saddlebag to house the motor controller and leftover wires, centralized within the bike frame triangle. Initially using zip ties for wire routing, I later switched to velcro cable ties for easier removal during tire changes while maintaining a clean aesthetic.

Battery:

Concerned about safety, I chose a 48V 13Ah dedicated ebike battery for its built-in BMS system and shorting protection. Mounting it directly on the bike frame, utilizing bottle cage mounts in the frame triangle, offered both practicality and a sleek appearance.

Next Steps:

To elevate the bike further, I have several ideas:

• 3D print an enclosure for electronics/wiring.
• Transform the bike frame into an enduro style.
• Modify the seatpost and toptube for a seating area.
• Install headlights for nighttime riding.