Full Build, No Talking: Vintage Honda Motorcycle Conversion to Electric.
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- čas přidán 7. 06. 2024
- 1967 Honda "Baby Dream" CA160 converted to electric/EV. QS hub motor, Kelly motor speed controller, LG Chem pouch cells.
For EVERY LAST DETAIL about this bike, check out my other videos in my project playlist: • Project Dream-e
Specs:
- 1.4kwh battery, 4kw motor (6kw peak), 72v system
- top speed: 55 mph (88 kph)
- range: 20 to 25 miles (32 to 40 km)
- charge time: 2.5 hours (6 amp/432 watt charger)
EV Components:
40 used LG Chem pouch cells from Batteryhookup
15ah 3.6v LG Chem pouch cells (when new)
200mm x 260mm x 8mm - or - 8” x 10.5” x 3/8” (with the plastic cases)
need to cut these 4p modules to two 2p packs:
batteryhookup.com/products/lg...
20s2p = 72v 30ah and 90amp continuous discharge rate (3c)
but if 2/3 capacity left, then only **20ah and 60amp discharge rate**
40 cells total, a four pack is $20, that’s $200 total
max voltage: 84v
min voltage: 50v
peak discharge current: 150amps ???
6.5kw ~= 72v x 90 amps (continuous discharge rate)
4.32kw = 72v x 60 amps (continuous discharge rate @ 2/3 capacity)
....
motor:
www.qs-motor.com/product/4000w...
maximum motor current at 72v: 90 amps = 6.4kw
continuous motor current at 72v: 55 amps = 4kw
...
controller
Kelly KLS7245N
90 amp continuous and 270 amp peak (phase current, which approaches battery current as RPM approaches max speed)
...
DC-DC converter:
20w from amazon
amzn.to/3M3UFV5
BMS:
DALY 100amp 20s 72v
Charger: amzn.to/3rnosi5
Contactor:
www.te.com/usa-en/product-161...
Kill switch: amzn.to/3NXKkKH
display: 72v charge meter from Kelly
Connectors and misc:
charger port: amzn.to/3BXeDfm
battery enclosure connectors: amzn.to/3fwSg93
wire connector kit: amzn.to/3UZbnc3
terminal covers: amzn.to/3ydIU8J
The loss of the aesthetic element of an engine has left many E-moto builders struggling to find ways to keep their bikes visually appealing. Too often has the engine been replaced by a blocky battery enclosure the size and shape of a Gateway 2000 PC.
But that was not the case for my latest project: a 1967 Honda CA160 converted to electric. The removal of the engine actually makes it look better as it lets that beautifully sculpted frame become the focal point. The curvaceous shape of the fenders, the square front-end assembly, and the angular, sharp lines of the stamped-steel frame are now fully on display.
One night I was showing my wife a picture of a Yamaha XS650 and a red Honda CA160, and I asked her which one she liked best. She said the Honda, but only if it was black. That night I woke up in my sleep and started looking at Craigslist for no particular reason. And then I found it! A black Honda CA160. I bought it the very next day for $500.
The engine was seized. Its the typical story: the seller's neighbor's brother left the plugs off after it lost spark and he couldn't fix it, and there it sat for over 10 years in the back of a barn. So with a seized engine, sculpted sheet metal, and a stamped frame good for hiding wires, this was the perfect bike for an EV conversion.
But I had another reason to convert it to electric. I wanted my wife to be able to ride a motorcycle along side me, but she doesn't know how or want to learn how to use a manual transmission. She is also really sensitive to the smell of gasoline and exhaust fumes, and she hates loud motorcycles with a burning passion. So this electric bike is perfect for her.
Riding it just puts a smile on my face, it's a very pleasant experience.
It's also much faster and quicker than my 200cc bike, but without any of the drama. You just hit the throttle and you're suddenly faster than traffic and there was no quake from the engine and roar from the exhaust. So the thrill is very different than that of a conventional bike with a gas engine.
And for that reason, the bike doesn’t appeal to everyone. Let’s just say the readers of Motorcycle Classics don’t have a lot of nice things to say about this bike. Yet the overall response has been very positive. My favorite is when someone sees it, someone who knows nothing about motorcycles, and they just look at it and see a nicely restored but otherwise normal, classic motorcycle. They don't even realize that it doesn't have a gasoline engine.
Song credits:
Crushin, by Audionautix
The Red Blouse, by The Matt Villinger Trio
Guitar Elation (can't remember the name of the song)
What a Wonderful World, by yours truly on a Wurlitzer electric piano
0:00 Disassembly
4:22 Unboxing
6:18 Battery pack
8:44 Swing Arm
9:44 Paint
10:48 Assembly
14:00 Seat frame
16:21 Battery enclosure
20:40 Wiring
24:41 Riding - Auta a dopravní prostředky
Phenomenal build, EV conversion, and most of all, video. The stop motion, editing, planning, is insane. Most people would not realize this unless they tried to make a similar video. This is pro level stuff here!
I love the way when you design the battery Box. It actually fit the 1960 style of the bike rather than just have a square Box jammed in there. Like everybody else does you made it look like it belong there right? From the sixties? Damn. Nice? Job I've always wanted to do this but there's something about the roar of an engine that I just can't get away from.
insane amount of work in producing such a flawless video
Yup. Supreme.. Such a pleasure to watch
Well... it's a question of viewership.
The stop motion works in many cases, but my honest opinion is that this kind of video doesn't need this.
The image and everything is really well filmed.
also.. NIN t-shirt.
The dedication put into filming this with the stop motions and all... Mad respect.
Thats the first thing I thought .....mad respect man
Same here. A monumental amount of patience must have been involved with making this video.
Omg right🙏🙏
Thank you very much!
Tell me, did you do one take and snapshot the frame or did u use a remote control?
Anybody who has the patience to restore a 56 year old bike has my respect. Anybody who is prepared to add the work of stop gap videography on top of that is too much for my brain to comprehend. So is the battery enclosure. Art, I'm telling you, it's feckin art!
The little warning labels are 100% important to this (not being sarcastic) ... I LOVE IT!!!!
Beautiful build video from beginning till end. Love how you blended the battery pack with the lines of the bike. Superb build.
Thank you very much!
This is crazy!! Build it self is not easy, making stop motion animation during build it another story. Thumbs up!
I remember this bike from my childhood
My dad's uncle had one
One day he was giving me a lift to school
On the way a monitor lizard crossed the road
In trying to avoid it we went into a ditch
The memory is stuck in my mind to this today
😂😂😂
The effort to time lapse this alone deserves all the praise I can give!
That's the first electric bike, I've ever liked. Looks great.
I have never seen anyone on CZcams put this much effort into production and video editing to make this type of "stop motion" effect for a topic that has nothing to do with animation. This is just phenominal and my hat is off to you because the amount of work to get this effect must be enormous, on top of actually restoring and converting the motorcycle!
I had a trashed scooter from 1958 with no motor, frozen brakes and fried electrics. Had someone convert it to electric. OMG it's the most fun bike ever. Should have done it sooner.
I love this whole project but the seat and rack are just the bomb! I used to own one exactly like this. Still miss it.
Man, this video is a work of art in itself. The bike conversion is another one. Two impressive results in one video 🤩
I'm more impressed by the stop motion than the bike build .. Nice job 👍👏
WONDERFUL !!! With the Fossil fuel prices skyrocketing, I feel this is a good video for people (if interested) can try this out on their motorcycles. I am planning to do this and convert my motorcycle to a Hybrid model (Petrol + Battery). EV drive to the front wheel to use it for city and congested traffic circumstances. Thank you for such a wonderful video
In 1964 i was 15. 5 and got a learner's permit........and a Honda Dream 150. Now i'm 75 and still ride, but on Triumphs. The Dream was my first love, however. i still dream about finding and restoring one. Glad to see that you did. They were extraordinarily beautiful classics that have never bean bested for good looks. 😊
An absolute work of art! I love how you designed the battery box to complement the curves of the frame. Genius!
Fantastic workmanship. Love what you did to the little beauty. Thanks for the video loved it. Cheers bud.
Rarely commenting, but this is definitely worth typing. Awesome build and video! 🎉
thanks!
This was an amazing build and video. I cannot imagine how many hours of work that went into the video itself. I speeded it up at the start and it was like magic happening before my eyes, brilliant!
Mad respect for your technical knowhow, craftsmanship, ingenuity, creativity. I always loved the style of the vintage Hondas.. you're the man.
Electric Dream! Fantastic building skills brought this vintage bike back to life and into the 21st century. Any motorcycle enthusiast would love to have this. I think you may've just given Honda Japan an idea to mass produce this product. Thank for all your hard work and bringing this to the public. Enjoy your new electric motorcycle.
Really if they'd let me, Two thumbs up!! great conversion. I have seen a number of motorcycle conversions but most want to go with the chain drive mid drive systems when the direct drive systems are so clean and bullet proof. No moving parts! the chem pouch battery seems to deliver good punch. Hope to see more of your work.
I'm researching an electric kids dirtbike conversions but now I want one for myself, you bastard, you may have just cost me thousands of dollars. Love it.
I had an old black 1987 Yamaha Virago 535 that I was thinking of doing something like this but I got rid of it during my last house move ! Oh man I'd wish I'd seen this video before I sold it for almost nothing. Your conversion is top class. The battery box shape is exactly in keeping with the original design. Well done. So many other conversions just have a huge square box to hold the batteries. Totally awesome work !
I really liked the project. I think you found a nice clean solution to the aesthetic issues and your wife's needs. Great video!
Amazing video work and shop skills my friend. I only wish you had restored this beautiful piece of history back to its original glory. I love that seat! Oh, I've been riding motorcycles ( owned 32 of them ) for 61yrs.
The stop motion start to this video is INSANE!!!!! can't even begin to understand the patience you had to create that! Thanks for sharing
Old Honda guy. Had several mid-late Hondas 63-68 305s same style. Love what you did, great job.
That's awesome! It fits the design of the rest of the bike so well, good job! :)
great build and video! really love the design and attention to detail.
Thank you! Cheers!
I absolutely love this. Every time I am browsing FB marketplace and such I see 2-3 hundred dollar bikes but sadly too many variables (space/skill/resource/knowledge) to try and tackle a project like this. Keep up the amazing and inspiring work!
You are amazing. I appreciate how you put a lot of effort into making this high-level editing video while providing great insight into the EV conversion process. I will try this on my old honda cub. Thank you.
Truly impressive. Nice work!
An outstanding bit of engineering! Wish you were my next door neighbor.
Does your neighbor have an obnoxiously loud motorcycle or car?
@@ThisOldJalopy No. I would just enjoy hanging out with you. :-)
This is the best resto video I've seen before. That stop motion is hypnotic.
The bike looks absolutely brilliant! Everything has wonderful curves and flowing lines. Keep doing what you do 👍‼️
Really good video, excellent workmanship, excellent choice of original machine too. I really admired the way you converted the original fuel tank. One tiny comment only, not trying to be a nit picker, I would have put the on off switch perhaps under the tank, but that's personal choice only. Congratulations to you. Thank-you.
Subscribed and liked. Thank you, man. There are few craftsmen/craftswomen now a days. You are one. Bravo! Bravo!. Transportation doesn't need to be as complicated or as expensive as a Tesla.
I'm looking forward to the days where conversion kits will be diverse, adaptable, plentiful and cheap. As battery technology improves, the batteries should become more compact and lighter.
I think the hub powered unit is the way to go, much less complicated, making stand alone motors and chains unnecessary for everyday putt putts.
Again, thanks for sharing your talent, bro,
rocket
UK here.
Great conversion. The Hub motor & battery case don't look out of place on that style bike either.
Just personal preferences, With your fab skills you could've made a BMW engine style battery case which could've given you a few more AH and maybe used a recessed round volt meter in the "fuel tank" ?
Great Job though and something I'd like to progress to from ebike builds.
Thanks for sharing this build. Beautiful job. Wheels are turning now.
Fantastic looking bike. Its lines are so in keeping with the original that the EVness of it doesn't jar at all. Great job!
Fenomenal trabalho com a moto e com o vídeo. Parabéns. 🎉
Not only an amazing and beautiful build but a super cool way to film it!
Riveting! Ever decision that you made was brilliant and stunning. Seat and carrier especially!
I had the 1966 Scrambler 160 which was my first bike back in high school. Fun but the suspension was super bad and I think I am still paying for it today. I actually broke both feet pegs during a small jump. I like the time lapse no hands video.
Great conversion! Excellent stop motion work also. Back in the day, I had a Honda CA77 Dream. It looked a lot like yours. I miss riding it sometimes. The purr of a well tuned engine is hard to beat, but maybe the motor whine of your conversion sounds good to you. Anyway, thanks for sharing your skills with the rest of us.
The 1970's solution is to attach playing cards to the fork that will make sound every time a spoke comes around. Clothesline pins were used for this purpose. 🙂
Great job, I owned (and drove daily, in college) a CA95 (also a 160cc Honda Dream, paid $50) , later I found a 66 CB72 , that was the 305cc (also paid $50, it was 1974) , it came with leather studded saddlebags. Loved that pressed steel frame design, vs a tube frame. I have two suggestions, replace the volt meter with a round/vintage appearing dial face. Also, maybe an older appearing Honda decals for the battery/motor compartment.
Best looking project I’ve seen so far! Tasteful and classy. Kudos for the time lapse animation too!!! 👏🏻👏🏻👏🏻👏🏻👏🏻
Love these frame by frame tear downs :) Great for learning
beautiful work... both on the project and the video. congrats!
Great music, video, great bike build! You could engineer a kit for DIY builders. It would be best to build the kit around a motorcycle that was produced in great numbers. I think it would be a great business.
Look I'm only 1:30 in and already in awe at the time and effort that has gone into the filming... congrats !
EVs have never really excited me but this thing is badass! Much respect to how you resurrected this old Honda. You've got my wheels turning now.
Great build mate. I have only one small thing to comment on. I think there will be problems with the cables somewhere around the pivotpoint of the swingarm. Copper doesn't like too much bending movement/stress. Kinda like cables in cars breaking on doors and trunks after a while. They don't see as much movement as a swingarm tough. But still. Great video, funky music and a stunning build
Edit: damn you autocorrect
Good point. The copper in the cables may get work hardened and brittle over time.
You can buy cables which are built for movement. They're used in CNC machines where the gantry is constantly moving back and forth.
Honestly, if any major manufacturer built a little 3kw city bike that looked even remotely as good as that it would instantly change the face of electric motorcycles. Yet, you see so many with their truly awful 'futuristic' looking machines.
Thanks so much! I'm bringing the bike to the Handbuilt Show in Austin next month if you'd like to see it in person
@@ThisOldJalopy Id love to, but I'm across the pond. So I'll just have to imagine instead
I had that exact motorcycle that I bought in 1970 as a basket case. After getting it running it was a great smooth riding machine. Loved the style.
just saw this video for a couple of minutes. paused it. subscribed and then resumed again. you got my attention instanty. very good stuff and great video editing. cheers!!!
The music is gross😢
What a Super Job Done, Reminded me of my own Honda 175CC back in my college days, I restored it as orginal on Gasoline in year 2000, and I really loved it watching you to restore, ahhh... SUPER DOOPER...AWESOME........ MAN... LUV IT LUV IT LUV IT.....May your hands do more good work.
Я думал что очередное видео реставрации или переделки уже не сможет меня удивить, но нет. Монтаж потрясный! Спасибо!
This was absolutely incredible, amazing job on all fronts
I bought CB 160 and had to sell leaving the country. When I returned I bought another, both 1965 models. Bestest bike I ever rode cos I lived on mountain roads in PNG and so fitted large rear sprocket. Can still hear that motor in my memory all these years later. They weren’t imported into Australia so won’t see one again....
I thoroughly enjoyed watching this build. My Dad had a Honda 300 Dream that was the source of many youthful daydreams.
You filled my head with ideas that will never come to fruition.
Please keep creating.
And change that seat for a “Springer” style.
Great work! Congratulations
This is soooooo beautiful. The amount of hard work that you have done for making this video is enormous....
what a beautifully made video. That must have taken a lot more effort than the build itself 🙂Thank you for sharing. You have been very generous to explain every step and list everything you've used.
I'm currently in Vietnam and they are so many restored CA 160's, or Honda 67's as they are known here. I recently was at a Honda 67 meet up, it was great to see so many old bikes in such great condition, no EV's though! Great video!
One the most amazing conversations I have seen to date on CZcams bravo
In the process of building my own. I love the retro look, and how you maintained that look. Awesome job, thank you for sharing.
Awesome! Thank you!
Back in 1971, at the age of 16, I bought a 1965 CA-160 305 Dream from a buddy. I rode it daily for 3 years and sold it for the same $150 I had given to buy it! I think about that old bike to this day, and if I still had it, I would absolutely do just what you did to this '67... a beautiful bike to start with, and a beautiful conversion on your part! Glad I watched the vid, and many happy and safe miles of cruising to you.
Оце мастер, оце трудолюб, дякую за відео, за демонстрацію вміння, силу волі, на таких треба рівнятись!
You must have the "Patience of a Saint"! (And a lot of time). The stop motion alone is so time consuming! I LOVE it!! Great Job!!
Wonderful modification to vintage electric bike. Simple,mi ute perfect work. One mans army. Great job bro.
I can only imagine how long this video took to publish, great job! Very nice job on the conversion as well.
I almost cried watching your first ride to "what a wonderful world"
What an awesome project. It was a pleasure to witness such amazing design and fabrication skills at work. Thanks for posting.
Love seeing old fossil fuel vehicles converted to electric ..amazing skills.
Sir, you set the standard for resto vids. I salute you.
Awesome build! Gotta love how quiet direct drive hub motors are!
Wow, the amount of effort that must have gone into this is insane. Bravo man, excellent build and thoroughly enjoyable video!
How did I miss your channel. Have to say you have great taste seeing a little of what you have around you bikes and car’s. Thank you for sharing 😊
Dude! Even the dents are straightened in stop motion??? I am shocked by the amount of time and artistry that has gone into this video. Most insane restoration video I've ever seen...
Excellent build and video!! Feels wierd to see a motorcycle on the road without the sound of the engine. Thumbs up for you!!!
WOW.
The engineering, the videography, the editing, and the project.
WOW.
I love how you put this together.
It's not my kind of thing BUT the amount of work, quality of the workmanship and the video override everything - amazing 👏
An amazing build, and a great video. Congratulations, I was blown away by it all.
Very innovative use of gas tank space, too. Again, I’m impressed.
I have to admit when the rattle can primer can came out I was concerned, but what a relief when the HVLP gun appeared ,well the results speak for themselves, wow, great thought went into this project and the details show. I'm a subscriber now.
What a BRILLIANT build 🙂
the fact that you film it in stop motion just wow, that had to take forever to film.
Just finish watching the video. Enjoyed the transformation from gas to electric you did a great job.
Very impressive. Really enjoyed the presentation and the quality of the bike you created. Thanks
Awesome build. Looks beautiful.
What amazes me is the video itself. It shows what true dedication is!
What a beautiful restomod. It looks gorgeous!
Respect. Editing skills are off the charts
❤ simply WOW. You have taken care of small small details...
What an awesome conversion. Loved watching this!
Outstanding build... well done !!!
Incredible build - well done
I can't tell which was more enjoyable: The build or the camera work! Well done!