Tom Stanton documents his three-year journey of designing and building a custom electric bike using innovative engineering techniques. Starting with a basic concept of attaching a drone motor to a bicycle, he progressively refined his design through multiple iterations, addressing challenges like motor mounting, power transmission, and battery configuration. His approach involved extensive experimentation, including custom 3D-printed parts, precise motor and pulley calculations, and meticulous battery cell selection. The final design features a 3.5-kilowatt motor capable of reaching 30 miles per hour, with a carefully engineered belt-drive system and a custom lithium-ion battery pack. Throughout the process, Stanton demonstrated problem-solving skills by overcoming technical obstacles such as motor synchronization, thermal management, and mechanical tolerances.
