https://github.com/timhanewich/ebike
Making my own eBike
https://github.com/timhanewich/ebike
Last synced: 11 months ago
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Making my own eBike
- Host: GitHub
- URL: https://github.com/timhanewich/ebike
- Owner: TimHanewich
- Created: 2024-07-07T11:24:08.000Z (almost 2 years ago)
- Default Branch: master
- Last Pushed: 2025-08-02T16:40:06.000Z (11 months ago)
- Last Synced: 2025-08-02T18:38:26.604Z (11 months ago)
- Language: Python
- Homepage:
- Size: 82 KB
- Stars: 1
- Watchers: 2
- Forks: 0
- Open Issues: 0
-
Metadata Files:
- Readme: readme.md
Awesome Lists containing this project
README
# eScooter
Homemade eBike.
**AUGUST 2025 NOTE**: leaving this project for now. It was semi-successful. With the gear design I had, I was able to get the bike to move under its own power several times. The gearbox was always the issue however. For different reasons it would fail. The last reason was the gears were just not strong enough being 3D-printed. I designed an entirely new gear design and printed everything, just to learn that the second gear rubs up against the flange (adapter) of the 3rd gear. Needs another re-design I just don't have the interest in doing right now as I want to move on to other projects.
## July 2025 Gear Redesign Temporary Notes
- Have to print:
- spacer1 is different, quite certain needs to be reprinted. (screw holes are slight different position)
- spacer2 is different, but see if you can get away with the old one.
- 608_cap_4 - totally different
- 608_cap_1 - totally different
- Confirmed to be same
- spacer3
- spacer4
## Configuration
- Bike: Schwinn SX2000 Mountain Bike
- [My actual bike](https://i.imgur.com/GaSKJRi.jpeg)
- [Online listing](https://www.propertyroom.com/l/schwinn-sx2000-mountain-bike/10507696)
- [Online listing on facebook marketplace](https://www.facebook.com/marketplace/item/3741195909458022/?_rdr)
- [This tutorial](https://youtu.be/Aj35ce6RfEM?si=b9BWHbFmZhSQtrBy) demonstrates removing the crank that looks like a square, like my bike.
- The largest rear gear has **28** teeth. This 28-tooth gear is about **4.5 inches** (approx) in diameter.
- The "rear pole" (the pole that I'm mounting the gear box on) has a diameter of 32 mm.
- The "bottom pole" (the pole the other two screws go into) has a diameter of approx. 48.5 mm.
- The two screws that screw into the frame for the water bottle holder are **M5*15mm** screws.
- Motor: Platinum 5230SL 190KV
- Listings:
- [On Hobby Wing](https://www.hobbywingdirect.com/products/platinum-fw-5230-motors?variant=42212563452019)
- [Marketing Page](https://www.hobbywing.com/en/products/Platinum5230.html)
- [Specs](https://cdn.shopify.com/s/files/1/0109/9702/files/pl5230-data.pdf?v=1724706933)
- [On Hobby King](https://www.towerhobbies.com/product/platinum-5230sl-motor-190kv/HWI30416200.html)
- [On Amain Hobbies](https://www.amainhobbies.com/hobbywing-platinum-5230sl-brushless-outrunner-motor-190kv-hwa30416200/p1578736)
- Voltage: 12S, but specs show it performing at 10S, so lower S's should work.
- 112A max current (stall)
- 4,895w max power
- Measurements
- Inner holes (M4) = 30mm apart
- Outer holes (M4) = 44mm apart
- It appears to use 4mm male bullet connectors, just like [this motor does](https://a.co/d/dk6BBRY).
- [Motor Coupling](https://a.co/d/3mqO0bW) used to mount the gear to the motor shaft.
- The 4 holes on the disc are 24mm apart from the opposite side (so 12mm from the center)
- [ESC](https://a.co/d/0q2reOV)
- Manual: https://maifile.cn/est/a660b60abe5735/pdf, but stored pictures of it [here](https://imgur.com/a/tfH6Hq5).
- I tested it at 4S, it works at 4S despite it saying 5-12S.
- Batteries: 3 [4S 3300 mAh LiPo batterys (60C)](https://a.co/d/cUkfjpm), in a series (effectively 12S)
- [5V Buck Converter](https://a.co/d/enad4n0)
- [eBike Thumb Throttle](https://a.co/d/3h9mEAN)
- [wiring](https://m.media-amazon.com/images/I/61KwWizb+DL._AC_SX679_.jpg)
- Hose Clamps
- [2.5" Clamps](https://a.co/d/6WDhVfk) are used for the motor mount on the bottom pole *(they say KSI on the lock)*
- 2 hose clamps from Ford's Garage (I think shorter than 2.5"... maybe 1.5"?) are used to mount the gearbox to the mid-pole (verticall) *(they say 304 on the lock)*
## All Development Media
- January 25, 2025: [Photos of Bike Before Modifying it](https://imgur.com/a/QJfTLXH)
- January 27, 2025: [Determining Motor Mounting Position](https://imgur.com/a/0CeCH1P)
- January 31, 2025: [Original Motor Mounting](https://imgur.com/a/6YDlS4K)
- February 2, 2025: [Motor Startup Hesitation](https://youtu.be/MqxyXDnDgKA)
- February 2, 2025: [Motor Running Test with Gear Shifting](https://youtu.be/jSprWTQn9RQ)
- Februry 28, 2025: [New Gearbox Mounted](https://imgur.com/a/rcUkqlp)
- March 12, 2025: [Shaft Slippage](https://imgur.com/a/C1VOYFI)
- March 15, 2025: [No More Slippage (notches etched into shafts)](https://imgur.com/a/ccalIE8)
- March 16, 2025: [Demonstrating Motor Connection](https://imgur.com/a/e7eUgE7)
- March 27, 2025: [Full Drivetrain Test](https://youtu.be/gY1TRV99fqI)
- March 27, 2025: [eBike Development](https://youtu.be/JQQ2eHjpAwc)
- April 4, 2025: First test run
- [All pictures](https://imgur.com/a/esqoKJy)
- [Video (edited)](https://youtu.be/8QopB0LM2to)
- April 27, 2025: Second Test Run
- [Pictures of damage](https://imgur.com/a/OvujgRJ)
- [Full Video and Pictures (unedited)](https://youtu.be/GyaS9Lfgngo)
- [Hairline fracture in gearbox mount](https://i.imgur.com/Xe3rbP3.jpeg)
- May 23, 2025: Third test run (with 608 bearings in gearbox)
- [Pictures of assembling gearbox before test](https://imgur.com/a/RMSh9od)
- [Full video](https://youtu.be/m6RZ3c31-8g)
- [Pictures of broken gear #2 after the test](https://imgur.com/a/yVf4q6Z)
## Inspiration
- [Tom Stanton eBike V1](https://www.youtube.com/watch?v=9rIIJbDkpN8)
- [Motor he used](https://hobbyking.com/en_us/turnigy-aerodrive-sk3-6374-149kv-brushless-outrunner-motor.html/?___store=en_us): $105, 149KV, 2700W, 12S
- [3D Printed Parts](https://www.thingiverse.com/thing:2191603)
- [Tom Stanton eBike V2](https://www.youtube.com/watch?v=IymLqEPUkvw)
- [This video](https://www.youtube.com/watch?v=V4ohWg4GfYc) describes designing and 3D printing a sprocket.
- [This defaileur pulley](https://www.thingiverse.com/thing:4677579/files) fit perfectly! (I printed and tried)
- Specs (reversed engineered): https://i.imgur.com/SSaZPZ7.png (10.28mm pitch?)
- I think these specs are wrong...
- I think the gear maker in Blender has its measurements off.
- When I make a gear with a 12.7mm pitch in FreeCAD and then import it into Blender, it matches this gear with apparently a 10.28mm pitch...
- Blender must have its measurements off somehow.
- So, anyway, if you design a gear in blender, I guess use a 10.28mm pitch because that is *actually* a 12.7mm pitch!
- I remixed it [here](https://www.thingiverse.com/thing:6930961).
- [Michael Rechtin made a nice stackable gearbox](https://youtu.be/G0DcM60lWSw?si=MsUi8FOoKw17uXnp)
- [20x27x4mm bearing](https://a.co/d/306vlTe)
- [45x58x7mm bearing](https://a.co/d/fQ6uB3k)
- [How to make a gear in FreeCAD](https://www.youtube.com/watch?v=8VNhTrnFMfE)