Cafe Racer (Electric)

Discussion in 'Other metal working projects' started by Robert, Sep 3, 2017.

  1. Robert

    Robert Silver

    I have spent about a month building an electric bike styled after the classic cafe racers. It is a blast to ride.
    Here is my inspiration:

    [​IMG]

    I can't match the beauty of that bike but here is my version!

    [​IMG]

    $120 out of China:

    [​IMG]

    I had this fork:

    [​IMG]

    Taking shape:

    [​IMG]

    [​IMG]

    Robert
     
    DavidF likes this.
  2. Robert

    Robert Silver

    Bottom bracket is my own design using conventional bearings:

    [​IMG]

    [​IMG]

    Derailleur hanger:

    [​IMG]

    Derailleur hanger and torque arms:

    [​IMG]

    Building a battery box. It has to fit the style of the bike. 4" tubing 1/4 wall cut in half.

    [​IMG]

    TIG welded:
    [​IMG]

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    Drilling holes using a template:

    [​IMG]

    [​IMG]

    Robert
     
    Last edited: Sep 8, 2017
  3. Robert

    Robert Silver

    More:

    [​IMG]

    Rewired this half twist throttle to work with my controller:

    [​IMG]

    Battery voltage indicated on the keyswitch:

    [​IMG]

    Chain line setup:

    [​IMG]
     
    Last edited: Sep 8, 2017
  4. Robert

    Robert Silver

    Done!

    [​IMG]
    [​IMG]



    Robert
     
    Last edited: Sep 8, 2017
    DavidF likes this.
  5. DavidF

    DavidF Administrator Staff Member Banner Member

    Thats one sweet looking ride!!
    Are you still going to do the seat? Looks like it would be troublesome to do and keep the ride height..
     
  6. Robert

    Robert Silver

    I am confounded by the seat. I need the seat to be height adjustable for various riders. If I build the Cafe seat that I was planning I will need supports going to the rear of the seat. That would interfere with the adjust-ability. I was thinking about making one that mounts on the standard seat post without supports, but I am not sure that would look good.
    Robert
     
  7. PatJ

    PatJ Silver

    Beautiful work Robert.
    Thanks for posting.
    What a cool ride.
     
  8. Robert

    Robert Silver

    Headlight:

    [​IMG]

    Robert
     
  9. Robert

    Robert Silver

    Mounting:

    [​IMG]

    [​IMG]

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    Still confused about the seat...

    Robert
     
  10. DavidF

    DavidF Administrator Staff Member Banner Member

    Im at a loss for the seat as well, but if there is anything I can do to help you out let me know..
    Your bike looks right at home in your living room! ;):cool::D
     
  11. Tobho Mott

    Tobho Mott Gold Banner Member

    Bike's coming along great! That headlight looks awesome.

    Jeff
     
  12. Al2O3

    Al2O3 Administrator Staff Member Banner Member

    Sure looks the part. Nice workmanship. Have you used it at night yet? Looks to be mounted on the traveling portion of the fork suspension. Seems like you might get a beam that dances all over the place with suspension travel and buzz around a bit in vibe on the end of your bracket. Isn't the norm to mount to the frame/sprung mass or maybe fork tubes between the triple tree?

    Best,
    Kelly
     
  13. Robert

    Robert Silver

    Thanks guys!
    Kelly- you are correct on all points. I took it out last night and it works fine. The mounting is very rigid and the beam does not move around very much. I thought I might need to attach it to the stem at the top but this is very satisfactory so far.
    Robert
     
  14. OCD

    OCD Silver

    Very Nice indeed.

    Well Done!!!
     
  15. Al2O3

    Al2O3 Administrator Staff Member Banner Member

    Good to hear. Well done. What's next? Any chance that empty fuel tank could hold rider refreshment?

    Best,
    Kelly
     
  16. DavidF

    DavidF Administrator Staff Member Banner Member

    Where's the beer holder?? o_Oo_O
     
  17. Robert

    Robert Silver

    I use this to go to the beer. Not to transport it....
    R
     
  18. Robert

    Robert Silver

    The seat I received is not optimal. It is narrow and uncomfortable. Probably not gonna work....

    [​IMG]

    I am also building a rack for the bike:

    [​IMG]

    I know, my TIG welds on aluminum are not stellar but they will hold.

    In other news the FTB goes electric also! I will post another thread.

    R
     
  19. OCD

    OCD Silver

    Sand it out and rattle bomb it flat black.
     
  20. Jason

    Jason Gold

    YUP, that seat literally looks like a pain in the balls!... Your tig work looks fine. Is it stuck together? No problem that a little fettling cant handle. (always wanted a reason to use that word)
    Grinder and paint, makes me the welder I aint!
     

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