Wooden E-Bike Prototyping Stages - Prototype Version 4

A brief overview of the steps involved in prototyping version 4.xx of an electric wooden bicycle for Renaissance Products Group.

This handmade bicycle project utilizes both analog fabrication and digital fabrication techniques. The Sapele wooden frame was created by laminating plywood to get one inch thick sheets to work from. They were milled digitally with Autodesk Fusion 360 CAD/CAM software and our large format gantry style CNC (which we also made). The Bicycle frame chain stay and seat stays were also CNC Milled, along with the custom aluminum dropouts. The round overs on all edges were down with a laminate trimmer. Notching and exit holes for the internal aluminum tubing for the brake lines, along with wiring, channels were cut in by hand. Sanding and finishing were done by hand. Final assembly of all the components was done by hand.

Follow Progress on Wooden Electric Bike Prototype Version 5 Here

Custom Handmade Wooden Bike
Custom Handmade Wooden Bike
Final Assembly of Wooden Electric Bike Prototype
Final Assembly of Bike Prototype
Assembling Sapelle E-Bike Prototype
Components on the Finished Frame
Panasonic 18650 GA 3500 Cells in Bike Battery Connections
Soldering E-Bike Battery Mount
Front Forks Installed on the Bike Frame
Front Forks Installed on the Bike Frame
Installing Front Forks on Sapele Wooden Bicycle
Installing Front Forks on Bicycle
Aluminum Dropout Installation Wood Bike
Installing Aluminum Dropouts
eBike Bafang BBS02 Motor Installed on Wood Electric Bicycle
eBike Bafang BBS02 Motor Installed
Satin Finish on Wooden Ebike Frame
Satin Spar Varnish Over Epoxy Finish
Gloss Epoxy Finish on Wooden E-bike Frame
Second Coat of Gloss Epoxy Finish
Press Fit Bike Steering Column Bearings
Press Fit Steering Column Bearings
Custom CNC Milled Bike Dropouts
Custom CNC Milled Bike Dropouts
Handmade Custom Wooden Bike Frame Glued
Handmade Custom Bike Frame Glued
ood Bike Seatstay Chainstay Fitting
Wood Bike Seatstay Chainstay Fitting
Bike Battery Wiring Channel
Bike Battery Wiring Channel
Wood Bike Frame Wire Tube Underside
Wood Bike Frame Wire Tube Underside
Clamping During T-88 Epoxy Glue up
Clamping During T-88 Epoxy Glue up
Painters Tape Before Gluing Frame Halves
Painters Tape for Gluing Frame Halves
E-Bike Frame Cable Wire Tubing
Tubing for Brake Cables / Motor Wires
Running Aluminum Tubing Though Frame for Cabling in Waynesboro VA
Aluminum Tubing for Shifter Cabling
Laminated Sapele Bike Chainstays
Laminated Sapele Bike Chainstays
CNC Jig for Side Milling Chainstay
CNC Jig for Side Milling Chainstay
Handmade Hardwood Bicycle Chainstay
Handmade Hardwood Bike Chainstay
Bike Frame Edge Routing Test
Bike Frame Edge Routing Test
Electric Wooden Bike Development in Central Virginia
Custom Electric Bike Development
Prototyping Product Iterations of Bikes in Charlottesville Virginia
Prototyping Product Iterations of Bikes
CNC Milling of Custom Wooden Bike Frame
CNC Milling of Wooden Bike Frame