Kyriakos, My Electic Motorcycle
Starting with an eBay mountain bike frame, I have made heavy modifications to fit a very large 10kW peak drone motor donated to my projcet by MITERS. This project called upon many skills, and this was my first project that included welding. Fitted with a custom battery, custom motor mount, waterjet foot pegs, and a custom hardware implemented precharge circuit.
The Build Process
Frame Modifications
The Mountain Bike
Kyriakos started as a cheap eBay mountain bike.
![](../imgs/kyr/signal-2022-07-13-13-57-18-254.jpg)
Welding and Painting
Since a large motor, electronics, and battery needed to be mounted, heavy frame modifications were needed. Use of waterjet, lathe, and mill was necessary to produce the parts according to my design.
![](../imgs/kyr/IMG_20220815_204641.jpg)
![](../imgs/kyr/IMG_20220817_231504.jpg)
![](../imgs/kyr/IMG_20220818_193819.jpg)
Sheet Metal Covers and Holders
Sheet metal was waterjet, bent, welded, and painted to make belt covers and holders for both the battery and electronics. I also made some footpegs with the same method.
![](../imgs/kyr/IMG_20220906_213156.jpg)
![](../imgs/kyr/IMG_20220915_130717.jpg)
![](../imgs/kyr/IMG_20220924_105441.jpg)
![](../imgs/kyr/IMG_20220915_160924.jpg)
![](../imgs/kyr/IMG_20220924_112213.jpg)
The Motor
This motor allegedly came off of a drone that fell in a lake many years ago. It somehow ended up at miters and then into my hands. This motor can output enough power to compare with a typical 125cc - 150cc engine.
![](../imgs/kyr/IMG_20220211_201857.jpg)
I also opted to install hall sensors into this motor to get zero speed torque, something that I would not want to be without on a vehicle of this size.
![](../imgs/kyr/IMG_20220709_204426.jpg)
The Battery
At this point I have had plenty of experience designing and building batteries from doing battery on MIT Motorsports. The bike battery is made from Molicell's P42A, a cell that definitely outperforms the current competition. This was definitely the most expensive part of the entire build, but this is not something I wanted to cheap out on.
The Gluing Process
![](../imgs/kyr/IMG_20220917_162946.jpg)
Spotwelding
![](../imgs/kyr/IMG_20220920_195245.jpg)
Insulation
![](../imgs/kyr/IMG_20220921_195942.jpg)
The Container
This is an ammo box I got from a friend who likes to buy and resell military surplus.
![](../imgs/kyr/IMG_20220920_215015.jpg)
Charging
I'm using a powersupply I crufted from the stata loading docks to charge.
![](../imgs/kyr/IMG_20220925_174913.jpg)
The Electronics
I am using an off the shelf vesc I got from projx as my motor controller. I also got a high current contactor from MIT motorsports that was unsatisfactory for the team. This is what I use in my precharge circuit to open and close the circuit.
![](../imgs/kyr/entire_electronic_diagram.png)
![](../imgs/kyr/IMG_20220922_225550.jpg)
![](../imgs/kyr/IMG_20220921_224328.jpg)
![](../imgs/kyr/IMG_20220924_000516.jpg)