It’s been a while since my last post. This doesn’t mean I haven’t been busy with the bike and a lot has happened. I just haven’t had the time to write about it. So let’s first try to catch up with what’s been going on.

Assembly

Once the paint dried up it was start to put things back together. This is probably the most enjoyable part and the least dirty as well.

Installing the battery

The battery holder is made to be installed using the threaded holes in the frame, that are meant for the water bottle holder. Unfortunately a military bike from 1942 doesn’t feature such holes. To solve this problem I designed and 3D printed holders that would be mounted to the frame using plumbing clamps. It turned out pretty good, I think, and the battery is now securely mounted to the frame. I had to use much larger bolts for the clamps which gave me a chance to use the milling machine at the Makers link for the very first time.

Let there be light 💡

This part was also a lot of fun. I really wanted to keep the original head and tail lights but hook it up to the ebike battery. I received a front light lamp with the ebike kit, so I took the LED and PCB from it and installed it in the original head light housing. For the tail light, I designed a 3D printed holder that would fit 3 hand wired LEDs connected in series, to make them work out of the box with the 6V light output from the ebike controller. Finally I mounted the 3D printed holder to the original tail light housing.