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Personal Project · Jun 2022 – Aug 2022

RYOBI Powered E-Bike

3D Printing Power Systems Weatherproofing Personal Project
Blue mountain bike converted to an e-bike with a hub motor and RYOBI 40V battery mounted on the frame
01 Purpose
  • Build a working e-bike for under $500 CAD, targeting a low-cost, environmental commuter.
  • Run it on a power-tool battery instead of a proprietary e-bike battery, for a low-cost, safe, and hot-swappable power system.
02 Process
  • Modeled and 3D-printed a custom battery mount to adapt RYOBI's 40V battery platform directly onto the bike frame.
  • Soldered and wired all connections between the hub motor, controller, and battery.
  • Weatherproofed the electronics — added a water-escape channel, dielectric grease on exposed contacts, and heat shrink to minimize rain damage risk.
CAD render of the 3D-printed e-bike controller enclosure with cable entry and mounting features labeled
3D-printed controller enclosure — cable entry, simple assembly, zip-tie mounting slots
Close-up of the printed battery mount installed on the bike's down tube
Battery mount features - curvature fit to frame, water escape feature, angled for access
03 Results
$565 CAD
Total build cost, incl. bike
30 km/h
Top speed
15–20 km
Range on 4Ah battery
  • Fabricated a custom e-bike running on RYOBI's 40V battery platform for $565 CAD, including the bike itself.
  • Reduced commute time by 20 minutes compared to the equivalent bus route.
  • Delivered a low-cost commuter with quick battery hot-swapping - eliminating range anxiety.
Ryan Huang — rhuang.caryanh1777@gmail.com · 672-999-9873

Gallery

3D-printed battery mount installed on bike.
3D-Printed battery mount installed on bike frame
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