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Saturday, November 12, 2011

Electric Bike Design

I wrote a post HERE in September about a electric bike that I designed, the E-Moto Monterey Electric Bike. There were a couple of pictures from the Las Vegas Interbike trade show that looked nice but didn't really highlight the unique features that this bike has. Below are some better shots of the finished product and some comparisons to the original CAD design that I did using SolidWorks.
Monterey Electric Bike (real photo!)
Monterey Electric Bike (CAD Model)
You can see some differences if you look really close between the CAD model design and the finished product. In case you can't see the differences I have more closeup pictures below!

Here is a closeup shot of the rear rack that contains the primary battery. In the CAD model there was bamboo side panels to cover up the battery a bit. The side panels were inside the rack tubes giving you a place to attach bungee's or straps to hold down whatever it is you are carrying. The finished product changed a bit but still has that functionality.

Rear Rack and Battery
The biggest difference between the CAD model and the final product was the addition of suspension. The original design didn't include suspension but at some point it was determined that the bike would be a better seller with the addition of suspension. Personally I go for a lighter bike without suspension, but that's just me!
Electric Bike rear Suspension

The front rack also can hide a second battery and has the bamboo wood cover to give it a nice look. The down-tube hides the cables that run from the handlebar controls and you can see the front suspension.
Electric Bike Bamboo Front Rack
Here are some specs:

MOTOR: 500 watt, high torque output, next generation geared, rear wheel motor (great heavy load and hill climber)
BATTERY: (stock) 36V * 10.5Ah Samsung 3C (high discharge rate) battery pack/ (optional) 36v * 7Ah Samsung 3C (high discharge rate) battery pack
CHARGER: 3+ Amp rapid UL listed charger
CONTROLLER: 25 amp continuous/ 30 amp peak 9 mosfet controller
INPUT: Twist and go throttle or 3 mode "speed sensor" pedal assist
RANGE: 10.5Ah stock battery 18 miles, or optional 7Ah battery 12 miles = combined total 30 mile range
SPEED: 20mph (32kph) extreme high torque output!
DRIVETRAIN: Shimano Alivio 8 speed w/ twist grip shifter, Freewheel range 11-32T
CRANKS: Prowheel OUNCE 248AE, 48T, cold forged alloy cranks
BB: Sealed cartridge by VP components
BRAKES: Promax DSK-715 (tool-less adjust) disc brakes w/ oversize disc rotors
MISC. COMPONENTS: Promax brand where applicable
SUSPENSION: Dual suspension, using front SR Suntour Nex-410 fork w/ lock out thumb knob
FRAME: 6061 aluminum w/ rear suspension 18" frame size (mid step over height)
WHEELS: 26" Double wall rims w/ eyelets, stainless steel 13G spokes, and Kenda Kontact oversize 26" x 2.125" brown tires standard, PR Tubes w/ Slime
FENDERS: Zeppelin fenders w/ stainless steel hardware
RACKS: Front and rear racks standard topped with marine grade bamboo plywood (both racks prewired for batteries)
I just wanted to share the pictures of the finished product. For other bike related stuff I have done click HERE and scroll down the the picture of the garage bike that I built. There are some links to other bike related things!



  1. Dear Otto,

    I am a french student in mechanical engineering school, and I actually work on a project the aim is to develop a new system to improve the security of e-bikes. I see that you did yourself a nice CAD model of the e-moto electric bike, and it is typically the kind of bike I have to work on. Could you possibly send me that model (.step or .iges) please?
    Thank you in advance.


    1. Johanna,

      Thanks for checking out my blog and I'm glad that you liked the bike! I can't send the CAD files because this is a custom design that I did for someone else. They own the rights to the design, even though I designed it.