Open Source Electric Bike and Car
~ designs in-process ~
12/23/2014
My wife and I recently sold everything and are traveling the U.S. in an RV with our three dogs and a cat.  I have a mini-fabrication shop set up in the RV with a 3D printer, desktop CNC and electronics.
Yes, we are environmental and electric vehicle hypocrites.  We sold our motorcycle and tiny cars and bought the Queen Mary of trucks.  Hopefully we will transition to at least partial biodiesel soon.  I hope that our total resource footprint is smaller now.  We'll discuss at ChangingStates2013.com
I removed a sleeper couch and table in the back room and made a work bench with storage and a dog area underneath.  Space is everything.  3D printer on the left and CNC on the right.
This is a TAZ3 3D printer from Lulzbot.com for $2300.  There are many cheaper, faster, bigger, better, etc. but this works fine and is well-suited to this job.  I have a supply of eight colors of PLA and some ABS.
This is a Zenbot 1624 CNC router from ZenbotCNC.com for $1100.  It will cut 12" x 24" sheets of plastic for 1/4 scale fabrication and it will also cut aluminum brackets for the e-bike.  Collet and bits from precisebits.com.
The e-bike project, called EZ-MTB, or maybe EZ-EB or EZ-EBike, is using a moped-type chassis with a mid-drive system.
The frame was purchased from Motopeds.com.  They have a frame kit shown here ($599) and a full-roller kit ($1999).  I am still waiting for the rest of the kit.  I originally ordered the frame kit and then upgraded to full kit.
The frame is a 2" steel backbone with an aluminum swingarm (with jackshaft) and aluminum subframe.  Very heavy for a bicycle but very light for a motorcycle.  Perfect.
The frame kit assembled and the drive in one possible orientation.
The whole workshop.  Glad the bike fits on the bench.
 Go to EZ-MTB page ...
The other project is the 1/4-scale EZ-EV open source electric kit car.  See these pages on this website for more information; http://www.zwheelz.com/EZ-EV.html

I already decided on a ready made front end and purchased the Heidt's Hotrod Mustang II front end kit.  It costs about $1300 and includes brakes, steering and suspension.  The first step for me is to put all the parts in CAD and print 1/4 scale parts with the 3D printer.
I decided not to bring the entire front end with us in the RV and didn't get a chance to get everything in CAD before we left so I took 3 view pictures and wrote dimensions on paper.  This is the upper control arm.
Lower control arm.
3D printed 1/4 scale upper and lower control arms, tire, wheel and battery.  I need to finish more parts and then restart the frame design and CNC cutting.
Lots of detail to learn with 3D printing.  Not how how to draw a part that can easily be printed but mastering all the settings on all the programs involved.