Building a Custom E-Mountain Bike (Part 1) with Paul Brodie - Framebuilding 101
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- เผยแพร่เมื่อ 20 มิ.ย. 2020
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This is a 3 part series in building a custom e-mountain bike frame.
► Click here for part 2: • Building a Custom E-Mo...
► Click here for part 3: • Building a Custom E-Mo...
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#ebike #framebuilding #custom #fussyframebuilder
I love the way kinda think out loud. I’m not a bike builder but rather a aircraft structure mechanic. I pick up tid bits here and there that would also apply to my job. Thank you sir.
Joseph, thanks for watching and commenting.
As a hobby frame builder I'm loving these videos! Thanks so much for sharing your knowledge with us Paul. We stand on the shoulders of giants after all.
I always enjoy the calm and order of Paul's shop.
Sounds like a compliment... Thank you very much!
Eyecrometer. haha. love it, can that be used along with the safety squint?
I enjoy these so much! Thanks a lot for the effort you’re putting in!
One thing you bring to your videos that others by and large don't do is your thinking process as you work on a piece. The why is many times more important than the what or how.
Jim, I agree. Thanks for watching :)
I just found this, and content is pure gold :) thank you I enjoy it a lot.
Brilliant stuff, I'm learning so many things from these videos. I always draw a centre line down the tube first with a sharpie and some angle iron and then end up ignoring it because it doesn't look right :)
Amazing build Paul. You are the master and your shop is amazing. Nice motos too.
You don't use grinder for cutting or sanding jobs! I love that! Congratulations Paul.
Thank you Freddy. I have watched too many TH-cam videos where the grinder cuts, slots, hacks, faces, blends, and seems to be the only tool in the shop, aside from the arc or Mig welder.
I love these videos. For the skill of fabrication sure but mainly for seeing the problem solving!
Julian, thanks for watching and commenting.
Great work Paul .... and Mitch! 👍
I just recently discovered your channel and have been working my through your videos, from the oldest to the newest. You're providing a fantastic resource here. I really like your teaching style and the videos are very well shot and edited. When I started learning about framebuilding back in the late 90's all we had were email discussion lists and a few online photo's to show how things were done. If a channel such a yours would have existed back then it would have blown our minds!
I will continue to catch up on your videos, and also spread the word amongst my framebuilding friends about your work here. Thanks for making this available. Cheers!
Alistair, in Seattle.
Thank you Alistair. Yes it definitely feels like the right time to be sharing knowledge, so Mitch and I will do this as long as we can!
Great video, great craftsmanship ... I never understand how people can give a thumbs down on this kind of content......
My thoughts exactly. Thanks for watching!
When I've had to bend up to a sharp corner before I usually start with a rectangular piece, put the bend in then trim it to size off a cardboard template... Usually takes two tries to get the perfect fit
Nice bit of work. Thank you.
Wow, this is amazing!
Love your videos Paul very educational, learning lots ,thank you 👍👍👍👍👍👍👍👍👍🤣🤣🤣🤣
I just discovered your videos and so glad I did!!! Im going to be commenting and thumb upping all your videos old and new :)
Thanks Rick :)
Great show, Brodie was a great start up. Congrats, making vintage proto's with 50's CWC steel frames. LOL!
Wish I lived nearby and was able to come and just see your work of art.
I just discovered your channel today (and I watched 8 videos). Though your reputation precedes you, before this I never put a face with a frame. Love it! keep up the great work.
Brian, thanks for watching 8 videos! Please tell all your friends :)
looks very good ! 👍
I enjoyed watching you have a nice work shop.
Like the small humour in your vids 👍
My first dual suspension bike was a Brodie Devo. Thank you for creating my childhood dream machine. 🤩
I had nothing to do with the Devo. It was made in Taiwan. But, thanks for watching...
@@paulbrodie lol I bought it because I was told it was made in Canada. Well, thanks anyway, there was no Brodie without Paul Brodie! 👍
There is a Lot of Mis-information out there...
After being on treatments for Lyme disease for 9 months I started building the frame for a 4 wheel drive and 4 wheel steer pedal kart from February 2016 to April 2016. I had to stop because the Lyme disease returned. I’ve been up and down ever since going on several different natural medicine antibiotics. It needs about $1,000 in machining splines on driveshafts. If I had more money I’d do the frame over again out of aluminum and make it lighter. My design has the ability to lock all 4 wheels in drive. It’s something I’ve wanted to manufacture but neither I or my family has much money.
Sorry to hear of your battle with Lyme disease. Life is not easy. That's great you had the initiative to start your project. I hope you finish it one day!
You are a true artist very detailed fit up.
Thank you Charlie.
Wow 😯
I guess the guys owes you a bit more than a pizza and a beer 😉
I was wondering about the second integrated battery too but the weight is already not a topic any more.
Anyway... cool as always ✊🤙
I enjoyed it!
Thank you.
Sweet. Building technique. It might be that Camara angle but the bike does not to have much slack. Can't wait to see the hole thing.
Some good craftsmanship 👌🏼
Thanks Mate.
Impressive, your digital eye micrometer with level option on the top tube water bottle feature. The steel rule scribe for the drop outs was priceless. A journeyman demonstrating what took decades to perfect, makes me think I could do that…then reality sneaks in when the video ends…
Ron, thanks for watching and commenting.
Awesome job 😮
Thank you Wayne! ...
The best thing is that Mr. Paul is crafting with a happy face.
So you are helping a engineering student do his or her required project, I now understand how we get so many unqualified engineering graduates . If he or she can't do the procedures necessary to complete the job they should not get the degree.
I'm not sure, but I believe he was getting marks for his design, not the execution. I think it was always understood (with the college) that a fabrication shop would be involved. But I do understand your point. Thanks for watching and commenting.
Love watching a master at work. The tongue sticking out even helps a master, good to know.
I try really hard not to stick my tongue out. Thanks for watching.
@@paulbrodie if it works it works 😋
I like it.
I am catching up on all the video's. This is unbelievable! What skill! The engineering student is building the e-bike? Ha!
Thank you Robert. Well, let's say that the Engineering student "designed" the bike...
@@paulbrodie That is impressive as well!
Love watching how you work, completely demystifies how it's done and what skills are needed. Are you originally British? Your accent seems to have a few British twangs to it or maybe I dont fully get the Canadian accent. Anyway, regards from the UK , love your work!
Yes I was born in Sussex and we moved to Vancouver when I was 9. Thanks for watching!
Great video
Thanks for watching!
@@paulbrodie alot of people have already said it , but yes great delivery patience & skill etc
Great work! That engineer student should get an A!
Thanks Al. I will recommend that for sure!
Some welding jobs benefit from a small gap with less distortion. Sheet metal body work for one but that's often done with a MIG. TIG with enough tacks doesn't seem as prone to the same problems. The one thing I did notice with perfect joints was that the order of the welds did make a difference. I have played around with tubes floating in free air and experimented with the effects of the welds but nothing that can compare with building a gazillion frames, I still keep luck on a monthly subscription.
A few flat files with one side smooth can be helpful when trying to perfectly match down tubes with bottom brackets. Modified several files with a surface grinder I had access to but although that wasn't really... is that a peacock?... I have found plenty of places to put them to use. Coincidentally, the surface grinder was purchased at an auction in North Vancouver.
Great videos sir and they are much appreciated.
Your comment just showed up after 2 months... Yes, I have 2 peacocks. I got my surface grinder from an auction too. That would be weird if it was the same auction. I think it was 2012...
Good job sir
Good to see more CArD design (see BadMotorsports Mini)
Maybe it's just me but I not enjoying the juxtaposition of curving and rectilinear geometry? Was making the down tube/ battery box with curves to harmonise with the existing curves and geometry of the Bosch pedal box housing not an option? I know I am perhaps being rather too critical but a well designed bike has to be both aesthetically and functionally pleasing? Are you aiming to highlight the difference between traditional and ultra modern? A sort of hand made robot!
Andrew, your comments are all valid. In this situation, I came to the rescue of an engineering student who needed to finish the manufacture of the e-bike for his graduating thesis. It was not my design, hope you understand...there was also a very short time period to get it done, after the parts ordered FINALLY arrived. Thanks for watching!
Would love to see the end and the e-bike on the trail.
You had me at "eye-crometer".
Very good!
Крутой байк!!! Палец вверх🔝🔝🔝
Not sure what you said, but thanks for watching!
Good 👍👍👍
dude explaining
the parrot: aaaAAAAAGH aaaaAAAAAGGHHHHH
I think you are referring to my peacocks...
oh so it was a peacock🤣
Great channel, resourcefulness, experience, and skill.
I wonder if you and the guitarist Eric Johnson might share a bit of genetic code : )
Thank you BrendaEM, I don't know much about Eric Johnson but I do know there was a couple of his songs that I really liked.
I noticed the Henderson (?) racebike (?!!) in the background - that would be a great topic for some videos, a nice walk-through b/c it's obviously very custom.
It a 1919 OHC Excelsior. I built 6 of them years ago. When we run out of bicycle projects we may switch over to Excelsior for a while... Thanks for watching.
@@paulbrodie wow! Where on earth did you find 6 similar 90+ year old motors?! I look forward to the moto content. IMHO, the bicycle content is secretly moto content for learning techniques.
@@Alanbataar That would be impossible to find six OHC Excelsior motors, seeing as there were only ever four made. So, I looked at old photos and created them. That became my Excelsior Project. There's a few photos on my website: www.flashbackfab.com
@@paulbrodie The penny finally dropped once I went to your site. I'd read your engine build "blog" maybe 10 years ago, and was very impressed. Two opposable thumbs up! Keep up the excellent work.
in Spain we use the Eyecrometer term aswell haha "Ojímetro" ojo = eye meter
Hello Spain... thanks for watching! :)
impressive work ;) did i miss mesures? lenght of bike, hight etc.. it would help me a lot, thank you
I became fascinated after watching a few of your videos by the meticulous process of problem solving that you employ. So your input would be appreciated.
Is there any commercially available I or T-beams shaped steel or aluminum stock, that could be utilized as a downtube member? And if not what flat stock would be the most appropriate, to create that shaped downtube member?
The purpose is to create flat surfaces to attach battery packs for an e-bike. I know that the downtube is in tension statically, but dynamically I'm not really sure. What's the most appropriate flat shape that would be applicable? Such a square stock tubing? It's just the bottom flange of an I or T-beams would be additional support for the battery pack. And it would give it a unique look. Any input would be greatly appreciated.
Extrusions are available. Search the Internet. If you going into production get a custom extrusion.That's what we did for our bicycle fork crown way back in the late 80s. Thanks for watching!
I'm enjoying your channel - was just wondering why not use a small end mill to cut the slot in the seat tube and then you'd have the endmill radius at the bottom of the slot in one operation. Is it important for that radius/hole to be larger than the slot width?
A small endmill tends to "wander". So you have to go slow, maybe take more than one cut. I also like the look of the hole being slightly larger than the slot, but not too much larger. Fussy! Using a slotting saw is just faster. Thanks for watching!
I need a friend like this¡! 😭
Brilliant work!
However, I would have put the batteries on top of each other to keep a slim frame where my knees are...
It was not my design. I was helping out a young engineering student so he could finish his thesis. Thanks for watching!
Hello Paul, im trying to build my own e-bike but having trouble with finding the correct size/measurment for the mid motor. Is there any blue print for building the “motor mount”?
That’s a beautiful Excelsior in the background.ls it a reproduction of yours? Engine looks interesting. Also the bike next to your workstation is that a knucklehead in a custom race frame? I had an idea to do just that. Looks great!
Yes, I made several Excelsiors, including the race bike with OHC Excelsior motor. 71 rear wheel HP from a 1919 motor. My website has some photos: www.flashbackfab.com
@@paulbrodie That era of motorcycles fascinates me. Effectively 100mph bicycles. Similar is on my long list of things to do. Unfortunately here in Ireland there isn’t a great supply of such old engines. I’ll check out the website. Thanks! 👍
I build hi power ebikes around 18 kilos. Weight is everything. I use aircraft aluminum.
E-ngagement!
Seems like a lot of weight,
but a 500+lb motorcycle 🏍️,
may add perspective...
Yesh, i would build it to a bosh 250w system, the bafang ultra would be perfect for this frame
these weights are insane. one has to lift that shit sometimes.
guess whether i just scrapped an alu gt xcr frame for making a second gen, brodie reactor based ebike for my wife... 500w rear wheel motor, enough batt to cover 50+kms @34km/h (like 30mi@21mph). frame currently at the local wizard's shop getting disc console and rack mounts.
Yes, there is a weight penalty for the electrical components. Thanks for watching.
If that battery box is the down tube between the steering / head bearings and the bottom bracket / crank., that is an excessive amount of weight to be carrying about., what 4 1/2 kg., in some bike designs., that member is a bowden cable., 'cos it spends NI on all it's in tension..You should get the guy to re look at his design..
All E-bikes have to carry the weight penalty of the battery somewhere. It wasn't my design, and I am not in contact with the owner / engineer.
damn i envy your skill
It's a process of learning. I have been making things out of metal for 54 years. Thanks for watching!
Hey buddy try use alcohol for tap tapping in alluThat’s work well
But I really like Anchorlube!
Paul you the man brodie!🔥 would you suggest a similar project but can it be done with a Flux core welder?
I have never used a flux core welder, so I unable to offer advice. Sorry.
If you're talking about a harbor freight quality unit i doubt it. Maybe the new green ones that are actually dc but the old black painted ones are actually ac and dont work well. Mind you high quality wire makes a big difference and ive done surprisingly good work with the old style harbor freight 110.
What type material do you use ?
Mostly cromoly 4130 steel..
Wow that is a beast. Why the double battery set up?
more range I am told :)
More range.........................
I have been watching your channel from your Italian race bike build. What is the bike on the wall above your head around 7;00 minutes in the video?
You have to tell me which video. I looked on both the Custom E-Mountain bike part 1 and the Aermacchi mockup video at 7:00 minutes and couldn't tell...
@@paulbrodie Video ; It is the
Where can one get those Bosch ebike batteries...
A good place to start would be the Bosch distributor in your country.
Why is the fit up so important? I mean up to using a feeler gauge. Its gonna be welded anyway right?
Because if you weld over a gap, it pulls and distorts. You do a nicer weld if there's no gap. It's all in the details.
@@paulbrodie ahh makes sense! Thankyou!!
👍👍👍👍👍🔥🔥🔥🔥🔥
Thank you...
how much would it cost to build a frame aluminum vs steel more or less, thank you
They are probably comparable in price, but the aluminum frame would also have to be heat treated, so that is an additional cost.
Surprised you don’t run the top tube through the battery pox and actually weld it to the head tube directly
I was working with someone's design; I was merely the fabricator...
Nothing wrong with over engineering
But over complicating is something else
I think simple is often best.
Very nice videos. The only problem is that youtube puts advertisment videos every two minutes.
Try an ad blocker.
How much the tickness of the plate?
If I can remember it was .065" 4130.
Alloy Steel 4130 (Chromoly) Steel Plate with 0.065 inch thickness right? Thank you @@paulbrodie
@@samurbandy Correct :)
Pea fowl powered workshop?
They are peacocks, but I have to feed them. They don't power my shop :)
Do you still do frame building classes?
Sorry, no. Covid put an end to that..
Why is the binder bolt on the front side of the downtube?
I think you mean the seat tube.. because if you ride in the rain it helps to stop water going down your seat tube.
I need to learn from you
Pls teach me
Teaching you through each and every video. Thanks for watching 😉
Hello, where did you get the Bosch Motor mount from? Thanks
I believe it came from Bosch. It's a nice casting but very heavy.
I also think it’s aluminum - hard to interface with 4130….
Any plans?
I have no plans to build another one. If you are asking if I have blueprints or drawings, the answer is no. Sorry...
Shouldnt the guy doing his finals be doing this ? I see now how i can have a boss that has manicured nails, highly qualified but if no one from the shop turns in, he wouldnt know a weld nozzle from a pen top
Totally agreed. When I did my degree we built our own stuff.
After I finished my apprenticeship as a fitter/turner/millwright, and fabricating our own off-road stuff for years, I worked for a time in the university engineering department, building things designed by students. Often there were fights with students about things that will just not work in practice, and these guys have rarely even seen a file. Used to drive me nuts...
Good story!
Привет из России!!!
Is this HIS project?,........or Brodie's and the fab shop?,........"he works haaaaard for the money"
I was just the fabricator, not the designer.
No issues with assembly for me th-cam.com/users/postUgkxHL1v1R3NE5x4KiYfyt8dnQmyNYz7qi5L but I could see where some might benefit from using an experienced bike assembler/mechanic. I'm an older rider starting back after a 10 year break. This bike exceeds my capabilities and has been easy to get comfortable riding. I'm mostly on easy trails with almost no street riding and have not been disappointed with the performance of the bike. My fitness level is far below what I previously rode with and because of that the mileage is going on the bike slowly. While I'm losing weight slowly, the bike seems to tolerate my 220 pounds just fine. The bike has been used by several family members ranging from 5'5" - 5'9".
If you pay enough money you can get insurance on almost anything.
what is the gauge of the sheet?
I don't know the gauge, but the thickness was .049", if I can recall...
that down U tube feels waaaaaay to heavy. could be half or less i believe. know it is not your design, just mentioning. nice channel.
Yes it was heavy, but being a U-shape it needed to be.
How did they buy the bosch motor?
The student had been working at Zero motorcycles in California, so he had a contact at Bosch.
@@paulbrodie I've contacted bosch, brose, and bafang with no reply. I'm trying to do my own build as well
@@MrHamncheez Good luck with your search!
how much do you charge to build e bike frame
Last time I quoted it was $50K...
You've got peacocks.
Yes, I had peacocks for for many years, but then I only had one male and he got lonely, so I gave him to a family of peacocks and now he is much happier. Hard to look after a peacock when I wasn't well 😉
@@paulbrodie @paul brodie I grew up listening to peacocks. My stepdad had all kinds of pheasants, currasows, doves, a 200 head ostrich ranch at one time, and of course peacocks. He also had to have back surgery in the 70's and thankfully was able to keep working and farming the rest of his life. I really hope you do make a good recovery and have some relief from any pain. I just discovered your videos and they are wonderful. Thank you!
@@matthewbarncord3984 Thanks Matthew. We just released a video yesterday. Our first in 158 days or so. Hope you like it 😉
Is that head tube not tapered? Weird to see a straight one on a mountainbike.
It's a 44mm Paragon straight head tube. You can call it weird if you like.
@@paulbrodie On second thought, weird might have been the wrong word. But unless he plans to run downhill forks on this I think most modern good forks are tapered, at least from looking at fox forks it seems that way. Or is this just a fad?
@@y0uRF4t3 Yes he's running a fork with a tapered steerer. You do not have to run a tapered head tube to have a tapered steerer tube. The tapered head tubes run the bearings on the inside; the 44mm Paragon headset runs the bearing on the outside. Make sense?
@@paulbrodie Oh, I've never seen that, thank you for explaining. Also I like your videos, keep it up! Do you know if he has a video of the finished project somewhere?
@@y0uRF4t3 The frame went to someone I have never met. No photos, sorry.
Paul... is that a peacock or peahen i hear?
It is a peacock that is in serious need of a peahen.
@@paulbrodie oh man i know that feeling. Bah dah ch!
doesnt wear gloves when tig welding, does wear gloves when using the bandsaw....... But nice craftsmanship!
I have promised to wear gloves for all future Tig welding that is being videod. (is that a word?)
@@paulbrodie no worry's man. I also find it more comfortable to tig weld without gloves 😂. Keep up the great videos!
The gloves can affect your manual dexterity. I’m fond of using Tig gloves for all welding, simply because I need all the help I can get that way.
He may wish to rub neatsfoot oil into his gloves, if he has trouble like I do.
With the weight of this bike,perhaps he should'nt have gone for the pedal assist,and put the motor in the back wheel,but love the build anyway.
Bending is hard, let me think about it, pulls out saw.....