Hello everyone!
We are Custo Bikes team from the capital of Russia – Moscow.
We are here to show you the process of building our electric bicycle «Rocket», (Ракета — in Russian). The bicycle was made in our workshop by a custom order.
Here are some specifications:
Frame`s material: aluminium
Electric battery compartment`s material: carbon
Components: Crystalite v.5 brushless electric motor, Russian-made «Adapto» controller, 72V 20AH battery.
Weight: ~50kg
Max. Speed: 80 km/h
Max. Distance run in cruise mode: 100 km
Max. Distance run at a full speed: 20-30km
Now let`s pass over to the construction process.
«Rocket» was made according to our usual practice. First step – choosing riding position, design development. Then we model frame and components in SolidWorks software (we used rhinoceros3d in past). According to model we make drawings and templates and print them at 1:1 ratio on A0 size paper. From those drawings we make needed parts. We have lathe machine, milling machine, pipe bender, welding units of different types, different hand tools. We outsource to our fellow Moscow masters various operations that can not be executed in our workshop, such as: CNC laser cutting, galvanizing, sanding, painting jobs.
During the making of this project we have not planned posting our story here, that`s why there are not many photos. And no photos of making battery compartment. Anyway, come and have potluck with us!
After choosing riding position and taking rider`s measures we are drawing a template.
On tracing paper we draw different variant of design concept
During the 3D model construction we focus on details and thinking over possible technical solutions.
Closer to final variant
Final variant. This one is used to make drawings and templates. Also 3d model can be tested to destruction.
We bend pipes, using manual pipe-benders. In order to avoid crease marks we fill pipes with silica sand.
The pipes are being defrazed
Tail just put together in a jig
Frame is ready
Before the painting we assemble the bicycle and test it, if everything is all right, we take it to pieces and only then send it to paint.
At first we tried to install Kelly controller, but it failed tests. Moreover, it was hard to tune. That`s why we decided to use Russian-made Adapto controller.
We changed cable routing a dozen times in order to put it all in battery compartment.
The customer took a ride and was surprised with the result. Felt like a light moped/scooter, weighing about 50kg. The acceleration of the bicycle can be compared to 125-200cc motorcycle. The max speed was limited to 80 km/h.
As a result – our customer asked us to add components for safe riding, such as direction signals and brakelight. The Rocket only benefited from these additions.
Here is the final image:
We are Custo Bikes team from the capital of Russia – Moscow.
We are here to show you the process of building our electric bicycle «Rocket», (Ракета — in Russian). The bicycle was made in our workshop by a custom order.
Here are some specifications:
Frame`s material: aluminium
Electric battery compartment`s material: carbon
Components: Crystalite v.5 brushless electric motor, Russian-made «Adapto» controller, 72V 20AH battery.
Weight: ~50kg
Max. Speed: 80 km/h
Max. Distance run in cruise mode: 100 km
Max. Distance run at a full speed: 20-30km
Now let`s pass over to the construction process.
«Rocket» was made according to our usual practice. First step – choosing riding position, design development. Then we model frame and components in SolidWorks software (we used rhinoceros3d in past). According to model we make drawings and templates and print them at 1:1 ratio on A0 size paper. From those drawings we make needed parts. We have lathe machine, milling machine, pipe bender, welding units of different types, different hand tools. We outsource to our fellow Moscow masters various operations that can not be executed in our workshop, such as: CNC laser cutting, galvanizing, sanding, painting jobs.
During the making of this project we have not planned posting our story here, that`s why there are not many photos. And no photos of making battery compartment. Anyway, come and have potluck with us!
After choosing riding position and taking rider`s measures we are drawing a template.
On tracing paper we draw different variant of design concept
During the 3D model construction we focus on details and thinking over possible technical solutions.
Closer to final variant
Final variant. This one is used to make drawings and templates. Also 3d model can be tested to destruction.
We bend pipes, using manual pipe-benders. In order to avoid crease marks we fill pipes with silica sand.
The pipes are being defrazed
Tail just put together in a jig
Frame is ready
Before the painting we assemble the bicycle and test it, if everything is all right, we take it to pieces and only then send it to paint.
At first we tried to install Kelly controller, but it failed tests. Moreover, it was hard to tune. That`s why we decided to use Russian-made Adapto controller.
We changed cable routing a dozen times in order to put it all in battery compartment.
The customer took a ride and was surprised with the result. Felt like a light moped/scooter, weighing about 50kg. The acceleration of the bicycle can be compared to 125-200cc motorcycle. The max speed was limited to 80 km/h.
As a result – our customer asked us to add components for safe riding, such as direction signals and brakelight. The Rocket only benefited from these additions.
Here is the final image:
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