Building a Fully Electric Cafe Racer Motorcycle | Moped

In this video I built a Fully Electric Cafe Racer style motorcycle/moped out of a 1977 Cimatti City Bike Moped. I stripped everything down to the bare frame and welded in a cross bar to support the gas tank. I also welded together a crank assembly in order to mount pedals as well as a disk brake system on the rear wheel. I reused the front brake hub from the original bike. I used a 2000 watt rear hub motor from NB Power and paired that with a 72 volt 20Ah battery. I also used a separate 12 volt 4Ah rechargeable power tool battery. The bike has a top speed of over 70mph, but I have the governor set to 69mph.
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[@danieldeponte2631]

In the welding you have to go a continuous line of 3 milimiter little jumps from beginning to end. Each of those jumps, create an interconecting pattern that acts as an extremely strong weave if you will.

[@bobkennelly8000]

don't breath in those welding fumes

[@cringram1003]

Make a shake down video. We know you spent a year building the thing but we just spent 30 min. watching you learning how to weld lol. Seriously make a test session vid we want to know how well it accelerates, top speed, range of a full charge, battery size ect. Also links where to buy those parts. Thank you in advance, good job and hopefully see you soon.

[@VanHoutenBuilds]

Yeah I'll film a follow up to it soon with all of the details and test drive!

[@andyfumo8931]

​@@VanHoutenBuildsnever happened 😅, that classic stang got you busy ehh

[@VanHoutenBuilds]

@@andyfumo8931 Yeeeeaaaahhhh. Whoops! I'll eventually make a follow up to this. But for now, I'm trying to finish up the mustang haha

[@matickovac]

That's a nice project and an impressive result, thanks so much for sharing. Would love to learn more about the total cost of the hub motor, battery and all other equipment, links to where you purchased it all, as well as details on how fast is the bike, what is the range and what acceleration does it achieve. Keep up the good work!

[@VanHoutenBuilds]

Thank you! Total cost of the hub motor, that was everything including the rear wheel and tire already assembled, brake rotor, controller, etc. was around $900. The battery is a 72Volt 20Ah and was about $300-$400. The Hub motor is a 2000 Watt hub motor, there wasn't much of a price difference at all between 2000watt - 3000watt. I chose a 2000watt thinking it would be more than enough, but hindsight should have gotten the 3000watt for more speed/power. My top speed is probably around 40mph. I haven't taken it faster than that b/c I'm still waiting on the registration to come through, I also have to get my M2 license. It accelerates very quickly, faster than a typical e-bike. The motor is also pushing about 75lbs, plus rider weight of about 155lbs. I bought the motor and battery from NB Power. I found them on Amazon and messaged them via whatsapp. They made everything to my exact specifications(rear axel length, and even battery measurement and shape) and helped me figure out what would be best for what I was trying to accomplish. I highly recommend reaching out to them.

[@nothingbutthisthatandtheother]

Great page great vids got to ask why would waste time using those cheap Li Ion packs? They are extremely bad quality and dangerous when you can get cheaper, much longer lasting and far safer LiFePo4 batts? I refuse to put these Chinese Li Ion batts on any of my hundreds of conversions. I have converted all of my vintage motorcycles and Vespas and Lambrettas to 72v 10kw motor wheel, Kelly Controller, 175 kph top speeds and 0-100 kph in 1.2 seconds and 80ah extreme range with 520 nm of torque which is actually 1 Nm = 3.7e-07 hp⋅h

[@VanHoutenBuilds]

I honestly didn't even know that was an option! This was my first time doing something like this. Where do you buy your batteries? Bummer you don't have any videos on you page of your motorcycles and vespas, would have loved to see them. Is there anywhere I can take a look at your builds?

[@barelytrine]

I love that you started with one of the most difficult welding process there is, it makes you a better welder.

[@VanHoutenBuilds]

Thanks! Totally agree!

[@SloppyLarry]

@11:45 just looking at that it looks like you have a good chance of getting wheel bite. Not pleasant on a skateboard probably really bad on a bike.

[@MrBallain]

How much did you spend on this project?

[@heavystarch100]

Jealous!👍🏾👍🏾

[@Maxttor]

well done Van Helsing, where is the final speed test? :)

[@VanHoutenBuilds]

I know! I'm going to do a road test video, I just have to go get my motorcycle license!

[@Maxttor]

@@VanHoutenBuilds Good luck! We are waiting...

[@LegacyThoughts]

Awesome build! I'm going for a similar look but keeping it gas. What fuel tank is that?

[@VanHoutenBuilds]

Thanks! It’s the peanut classic tank on eBay!

[@powchainsamaniego6744]

Dope and when you get into electric world?

[@alexarmstrong1134]

👍😎👍

[@rfdunbar]

Impressive what you were able to accomplish as a beginning welder! I cringed when you said stick welder 😆. Great job! I build all kinds of things so I don’t mind seeing content other than guitars.

[@VanHoutenBuilds]

😂😂 stick welder…thanks. Yeah I’m still learning!

[@greenlog7023]

What’s wrong with stick welding?

[@hamsterSNAKE]

Dude! Put an RFID RECEIVER under the seat cushion. You could have a button to push to scan....and just put the matching RRFID CHIP ID number to a card In your wallet. Sit down to steal it , it woundnt would have no idea. Or build in a safety pedal under the seat cushion that will trigger an elecritc braking system to engage making the wheels to also lock up if they where straddling the seat trying to push. But the only way that bike moves is by pushing it down the streat on a 45 degrees. That would every attention grabbing too....when build in a Air Tag....wire to battery.🤯 to stay on while there is a charge. My BRAIN!!! ITS GUNNA EXPLODES! CROUCH QUICK START🤯

[@alicemoon9008]

Great 👍 Job - Good Video ….. Hi 👋 from Chertanovo Chopper’s Custom Club ….. Moscow City 🌆 ….. Russia 🇷🇺 …..

[@ebikeengineer]

That's the cleanest conversion I've ever seen. Brillian use of the gas tank to cover the controller AND act as a charging port. I've also got to say great reuse of the drum brake on the front hub. I have to ask why the use of a 2KW hub rather than a 5 or 8 KW? Was it for legal reasons (moped laws vs motorcycle laws) or budgetary restrictions? After riding on the 2KW do you think that was the right choice?

[@VanHoutenBuilds]

Thank you so much! So when it came to the 2KW hub, I did it for speed. So I didn't want something super fast, but it also goes a little slower than I calculated. I thought I would be able to get around 40-45mph. Top speed for me is around 35-38mph. That's after the weight of the bike, battery, and rider, which I did not factor for. I should have gone a bit higher. But also I would have needed larger brakes probably, b/c any faster and they probably wouldn't be able to handle it, at least a larger disk in the back. But part of it is for legal reason and the gray area around e-bikes and mopeds in CA. I didn't know what I could get away with really. I mean I even went to get an M2 license for it at the DMV recently and they hadn't even heard of that and told me I couldn't get one, and that I would just need to get an M1. Luckily I was able to get it registered as a custom moped with a title so I could insure it. If I did it again I would probably opt for more power, bigger motor and bigger brakes.

[@marcirajkai8395]

the bike looks really sick, man! i hope you'll do more guitar stuff on here also ;)

[@VanHoutenBuilds]

Definitely got a handful of guitar videos coming your way soon!

[@S30Uploads]

I have like 14 vintage mopeds and about $10,000 in lithium batteries I think I should do this

[@mr.stephenchase7533]

Can you list the parts and the links? I want to give it a try as well... THANKS FOR THIS!

[@damirpaluska574]

Great build man ...i'm interested what kind of milege on average you get on one charge? I'm real noob at this, just started to explore the world of electric motorcicles.

[@VanHoutenBuilds]

Thanks! I can get around 40-50 miles on a full charge. It all depends on if I'm going full throttle as well as the temperature, and wattage I'm using, climbing hills, etc.

[@markryanbautista1137]

can you send the material and parts that you use iwant to build just like that a retro e-bike in the Philippines

[@cliffordbertin2649]

Beautiful cafe racer keep building thank you

[@crnogor]

You should jump over REL /electrode welding / from the start ! I can't take that you couldn't find some affordable TIG welder , let me say 400 -500 $ , build up a skills on scraps and that's it ! Argon mix ( for steel ) gives nice spread , deep and shallow welds plus , you can return back with out adding wire , just with a welding head , to repair weld / to make more melting down , if you 'r not glad with result ! In Croatia , on a test , they could be very picky and precise if we are making any changes or making motocykle frame from scratch . They , for sure , could ''record '' welds with ultra sound probe !

[@fu5593]

20Ah battery for charge to full power have to take how long? and 20Ah full battery can run how many km? if use 4000 watt rear what kind of NB Power and paired that with a 72 volt 20Ah battery can use? Thanks your video share.

[@dnjones3685]

Great design. Welding. Practice

[@willowbrookcustoms]

Awesome build! I completed a very similar project on my channel a few years ago. Very cool to see you working through many of the things I experienced. Keep building more bikes!!

[@VanHoutenBuilds]

Thank you so much! I'm a fan of your channel. I watched all of your bike videos several years ago when I was preparing to do mine!

[@gevnerovaolya]

Looks great! Or shite, actually

[@mckenzig1]

Very cool - I have a loaner bike and have been thinking about an EV conversion for a while, your video got me excited to start. Is there an option for regenerative braking from the NB power guys? I see you left a drum brake in the front and the disk brake in the rear comes with the motor I guess?

[@VanHoutenBuilds]

Thanks! Yeah, they have that regenerative braking option. I requested the rear disk brake on the hub motor. You can discuss everything with Anne via whatsapp. They will customize or help you customize everything to your exact specifications!

[@jeremyfagergren]

NB Power lies. They sold me a 40amp controller, but sent me a 20amp controller and then wouldn't send me what I bought. Then, they tried to convince me that the 20amp controller is the same as the 40amp. I will NEVER buy from them again. Buyer beware.

[@VanHoutenBuilds]

That's a bummer, sorry to hear you had a poor experience with them. My experience was really pleasant, so I can only speak to that.

[@brettkarling5671]

Have you been able to get a top speed and range of the bike yet? Would love to know really want to build one myself here soon.

[@HunterVanHouten]

Yeah so I just got it registered with the DMV, so I haven't been able to ride it much until lately! I gave it a bit of a speed test with me on it and calibrated for the smaller wheels. My actual speed ended up being around 35mph on flat terrain throttle wide open. I was aiming more for around 45mph, before I started the project, but forgot to account for weight of the bike plus rider. So knowing that, if I did it again I would definitely go with a 3000W - 4000W motor instead for faster acceleration and overall top speed. I would also use a larger frame b/c going any faster on the small moped frame could get a bit sketchy haha. Who knows in time I may upgrade it. Otherwise I have two vintage Harley Davidson motorcycle frames and I may try a ground up build with those and a much heavier-duty electric motor.

[@brettkarling5671]

@@HunterVanHouten Thank you that helps a lot! If you update it or do another build up make sure to capture it so we can watch!

[@DeepVIDesigns]

those small flux core wire feeds are not for the faint of heart. If it will take a shielding gas that will make your life FAR easier.

[@polartsang]

i love that you go all the way to build a battery box but decide to use zip tie to secure it lol

[@sterlingowens5744]

Did I see a flat screwdriver?!?

[@GIBBODJ1982]

Hi what hub motor and controller did you use

[@VanHoutenBuilds]

I used a 2000 watt motor and controller from NB Power

[@tuguybear930]

My first attempt at stick welding was way worse than than that. I was making a car trailer. I used it for years before I sold it and it never fell apart so I think you'll be ok.

[@tiagoguerreiro2309]

what brand of flux wire are you using?

[@VanHoutenBuilds]

Whichever one came with the welder! So I guess some off-brand Titanium wire? I use the wire they have at Harbor Freight too.

[@normanwray1341]

Hello sir,wow good idea let's see what you are doing now 😂🎉

[@SloppyLarry]

Nice bike one yr build. How much was the over head!?

[@DuanDao]

Pretty cool project

[@F.O.GFatOldGuy]

Cant find the website to order the motor. Do you have a link?

[@VanHoutenBuilds]

I did not order from a website. I found the seller on Amazon. NB Motors and then I messaged them. They sent me a WhatsApp number to contact. I did all my communication through whatsapp with the seller. They said I could either purchase through Amazon or via a paypal invoice. I chose a paypal invoice and they kept me informed during the whole process of my order.

[@F.O.GFatOldGuy]

@@VanHoutenBuilds awesome thank you. I'm using a '73 AMF moped frame and don't want to play a guessing game.

[@VanHoutenBuilds]

@@F.O.GFatOldGuy I hear ya. Yeah it took me months of communicating back and forth with the supplier. They helped me with everything, battery power, motor wattage, they even custom built the battery to my exact dimensions for no additional charge. They gave me a choice of 3 throttle options as well. They also took pictures of everything and sent them to me as they were being built. I also had them custom make two wheels for me so that I could use my existing front hub. I used Reed Bingham's videos as a reference and also reached out to him when it came to electrical. Depending on what you're using this for, I realized that a 2000 Watt motor only gave me a top speed of around 35mph. Hindsight, I should have gone with a 3000 watt hub motor.

[@jonboy8181]

I’d love to see you ride this for more than 0.2 seconds at the end! Speed? Power? Thoughts?

[@VanHoutenBuilds]

I know, I'll definitely do a follow up video to it with my thoughts. Haven't really been able to ride it much b/c I need to go get a motorcycle license first!

[@petermclaughlin3292]

I'm A guitarist as well you got me inspired thanx.

[@jerryweaver2247]

Pro tip on the welding. Get a professional and buy him a case of the best beer and an hour of hands on personal coaching will make you a good welder.

[@VanHoutenBuilds]

Haha thanks! If you know of one in the LA area, please send me their way! I definitely want to learn to be a better welder.

[@dtjs61]

What is the cost of the kit to build ?

[@VanHoutenBuilds]

It wasn't a kit, I bought everything individually and pieced it together. The only thing I bought together was the motor, battery, controller, and wheels. That was about $800 altogether.

[@danmiddleton6767]

No such thing as an electric cafe racer, not exactly what the guys stood for racing from cafe to cafe,

[@VanHoutenBuilds]

Yeah, I think the term cafe racer has taken on a different meaning nowadays. I think the term is moreso used to describe the unique aesthetic elements of a bike, which was inspired by those early days of racing from cafe to cafe. Honestly it has more elements of a brat bike anyways. Let's just call it a bike that was inspired by a specific "style."

[@Jamal-yl5he]

where can i get this hub motor

[@VanHoutenBuilds]

I reached out to NB Power via Amazon and then started to discuss specifics via WhatsApp with them.

[@Vuvuvu75]

Impressive man! I'd like to convert an old cafe racer to electric. This vid was inspire ng!

[@VanHoutenBuilds]

Thank you! Yeah I've got a couple 1950's Harley frames that I was going to try and build out into more electrics, but I'm running out of room in my garage. haha. It's so much fun, I would highly recommend it! All you need is a bike with a junked motor or no motor. You can also re-title the bike as a custom build if you put a new VIN on the electric motor and the frame. That's what I did.

[@chasetheworld7176]

Are the wheels 20inch ?

[@VanHoutenBuilds]

They are actually 16" wheels, pretty small haha. My 56 BSA has 19" wheels

[@ddlonglegs]

Great video! but where's the test drive..?

[@ahmedshaikhani8571]

Everything was going perfect, till you added cycling pedals :(

[@VanHoutenBuilds]

That's only so I can legally ride on the bike paths around LA! Way quicker and safer than weaving through traffic!

[@BadassEFdriver]

Would love to see more riding footage

[@ReedBighamBuilds]

Yo!!! Thanks for the shout out! I just saw the video and I am so impressed! This thing is looking so amazing! Enjoy the sick bike!

[@VanHoutenBuilds]

Thanks for the inspiration and all of the help! This was super fun. Already started on a few more bikes now haha.

[@ReedBighamBuilds]

​@@VanHoutenBuilds Can't wait to see them. It's addicting isn't it?? I have actually recently revisited my bike project and am redoing the battery compartment to make it a bit safer and nicer looking. I am a huge fan of the light-weight moped builds like those on electric moped emporium. Your bike is 100x cooler than when it started! Hats off!

[@VanHoutenBuilds]

@@ReedBighamBuilds thanks man! Yeah I saw your new battery compartment video! What you built looks awesome! Yeah the moped was a good stepping stone. Now I’ve moved onto a 57’ BSA Bantam and then have two 1953 Harley frames to maybe do something with. Too many projects!

[@williamindelicato2564]

Nice video. I tried looking up the other maker you mentioned, "reapium"(?), but I couldn't find a e-cafe build.

[@VanHoutenBuilds]

Here is his channel! www.youtube.com/@ReedBighamBuilds

[@williamindelicato2564]

@@VanHoutenBuilds Thank you so much! I royally messed up the name!

[@VanHoutenBuilds]

@@williamindelicato2564 I probably just didn't say it very clearly in the video haha

[@davidmiller4758]

It looks great but with only 4 ah battery I wouldn't expect more than like 5 miles lol. Why not build a bigger battery to go inside the tank, then mount the battery under the seat or tank ir build a box like the one for the battery. Looks great tho

[@VanHoutenBuilds]

Thanks! It's actually a 20ah battery!

[@davidmiller4758]

@@VanHoutenBuilds o ok thats better lol. It says 4 in the description

[@VanHoutenBuilds]

@@davidmiller4758 Whoops! Thanks, I'll fix that!

[@ashmc84]

Did the tail lights come with your kit or was it separate? Curious what make model it was. Thanks.

[@VanHoutenBuilds]

I bought the tail light separate off of amazon for like $12.99! Search on amazon: FEIFEIER 12V Motorcycle Integrated Brake Tail Light Turn Signals License Plate Bracket LED Universal Motorcycle Tail Light (Black Bracket Smoked Cover). The "kit" I got, wasn't really a kit. I just reached out to Anne from NB Power via what's app and we talked through everything I would need. They pretty much just custom made everything I would need and added in things I wanted.

[@ashmc84]

@@VanHoutenBuilds thank you. Great build by the way!

[@gregw6353]

Great video I was wondering what size hub motor did you use and how did it go

[@VanHoutenBuilds]

Thanks! I used a 2000 Watt hub motor and provided NB Power with my drop out measurements and they built the motor around that! It went really well. Adding the torque arms helped to really lock the rear axel in place. It's so much fun to ride! Already started another bike build haha.

[@jtnema1550]

Where did u buy the electric battery or set to make the electric motorcycle? Thanjs

[@VanHoutenBuilds]

NB Power

[@jtnema1550]

@@VanHoutenBuilds thank u

[@obeii1805]

Build my e bike?

[@AtoZtechsolution]

Nice bhai

[@kmuralikrishna1582]

Really appreciate

[@ebikeoutdoors]

Great bilud really cool ebike

[@VanHoutenBuilds]

Thanks!

[@jonlad0]

Hi! Pretty good job! I did a very similar conversion with the same hubmotor. But after a few kilometers of Test riding the six screws which hold the disc brake became loose. Do you have the same problem? First I thought the bike is too heavy for this small disc brake but I think yours is at least the same weight. Greeting from Germany, maybe you can help!

[@VanHoutenBuilds]

Thanks! I noticed that they were a little loose and so I tightened them down, also coated them with an anti slip which help a little I think. We'll see how they hold up over time.

[@jonlad0]

Thanks for your answer! I will try to fix the threads with helicoils, so I don’t have to buy a new motor! Hope it works and also that your motor stays intact!

[@GrimesGarage]

I would definitely recommend using loctite when installing

[@elelegidosf9707]

Description says "Over 70 mph top speed" 🤣From a 2kw motor? Errrm..... no......

[@droidking614]

Really? 1 second of riding it?

[@VanHoutenBuilds]

I know, I know....I just got it registered and still need to go get my motorcycle license. Once I get that, I'll post some riding videos!