Amazing things happen in this wonderful world, which is beyond our imagination. Often such events come before us, which we find unbelievable. Have you ever imagined that a bicycle can be made out of PVC pipes? Yes, I didn’t think so before either. But suddenly one day I felt like making something new. At that time I had a piece of PVC pipe in my hand and in front of me was an electric bicycle I had made. From this came the idea of making a bicycle out of PVC pipes. Without thinking about anything, I went to the market and bought a 1.25-inch gauge PVC pipe. The work of making PVC bicycles has started. Many people commented during the work that this bike cannot be run. It will break when you get on the bicycle, how many more? But I did it well by making this PVC bicycle. And used for a long time. I have discussed below the details about how I made this PVC bicycle, and what materials are required along with the PVC pipe.
Materials:
PVC pipe and other materials are required to make this PVC electric bicycle. Where I have collected these materials, and for what purpose I have used them, I have discussed them in detail below.
PVC Pipe:
I used PVC pipe to make the body of the electric bicycle. PVC pipes are of various gauges. 1 inch, 1.5 inches, 2, 3, 4 inches, etc. There are different qualities in this pipe. Some are very strong, some are less strong. I used a 1.25-inch gauge strong PVC pipe to make the body of this electric cycle. I used a PVC elbow and tee connector to connect these PVC pipes. This pipe is available to buy in the local market. Prices are different according to quality. I bought this pipe for Rs.50 per feet. I needed about twenty feet of pipe to build this cycle. The price of this 20 feet pipe is Rs 1000.
Electric Bicycle Conversion Kit:
The most necessary part to convert a normal bicycle to an electric bicycle is an electric bicycle conversion kit. The motor, controller, and throttle are available together in this kit. But the conversion kit I bought also had a pair of wheels.
Magnesium Alloy Wheel:
When I was searching online to buy an electric bicycle conversion kit, I saw that gogo a1.com offers a conversion kit with a pair of wheels. The specialty of these two wheels is that they spoke less and one of them a hub motor is fitted in the center. That’s why there is no trouble in opening the spokes and fitting the motor in this wheel. Being spoke-less, the wheels also look much nicer than regular wheels. Both these wheels have a diameter of 26 inches and weigh 450 grams each. It is made of magnesium alloy.
Disc Break:
Another feature of these two wheels is that they are fitted with disc brakes. Which makes the braking system stronger.
Hub Wheel Motor:
The hub motor fitted to this magnesium alloy wheel is 36 volts and 250 watts. This 15 amp hub motor can rotate 290 times in a minute without any load.
Controller:
The most important part of this electric bicycle conversion kit is the controller. It controls other parts like the motor, throttle, etc. Also, connectors for horns, lights, etc. are available from the controller.
Lock:
A lock is used to on and off all parts associated with the conversion kit.
Battery:
The battery pack used in the electric scooter is made up of 40 lithium ion battery cells. A pack is made by connecting four battery cells in parallel and total of 10 such packs are added in series to form the Total Battery Pack. Each battery cell is 4.2 volts and 2.7Ah. Since every four batteries are connected in parallel connection , in that case the voltage of each pack is 4.2 but its amperes will be (2.74)=10.8Ah and since such 10 parrallel batteries are connected in series connection the voltage of the total battery pack will be (4.210)=42V . Total cost of Rs 8000 rupees has been spent to make it.I bought battery cell and BMS online.
How to Make:
First cut nine PVC pipes to specific sizes. I will make the bicycle body by connecting these pipes. This requires seven T-Connectors, eight elbow connectors, and two +(plus) connectors. By applying glue to the ends of the pipe, I connect them by the connector. This is how I made the body of the bicycle. The ends of the pipe where the front and rear wheels will fit, need to be flattened. Otherwise, it will be a problem to put the nut on the edges. For this reason, we flattened the pipe heads by pressing them through the machine. I drilled holes in those flat areas to fit the wheels. Then I fitted the wheels. The hub motor was already fitted in the center of the rear wheel. Then I fitted the battery and controller in the middle of the body. One by one I fitted the key-box, stand, throttle, and horn in certain places. I fitted a suitable seat for sitting. I connected the motor, battery, and controller properly through the wire.
Cost:
To make the PVC electric cycle, I calculated my expenses.
PVC Pipe – Rs.1000
PVC Pipe Connector: Rs.800
Electric bicycle Conversion Kit with wheel- Rs.15000
Battery Pack – Rs.8000
Others: Rs.200
Total – Rs.25000
Specialty:
I made the body of this electric bicycle totally with PVC pipe, which is not commonly seen. Usually, the body of the bicycle is made of metal. Otherwise, it is not strong. But I made a strong body here with PVC pipe and it does not rust. It attracts everyone’s attention. Besides, Bicycle wheels are usually fitted with spokes. Alloy wheel is mainly seen to fit on bikes, not commonly seen on bicycles. I have fitted alloy wheels on this electric cycle, which is a bit fancy. This alloy wheel is the specialty of this electric bicycle. Since it is made of magnesium alloy metal, this wheel will not rust.
