Electric Dirt Bike Build Ep.2 | Chassis & Suspension - Tube Bending - Laser Welding
James Biggar 21:40
180,003 views · 4,181 likes Watch on YouTube ↗
Welcome back folks — this is Episode 2 of my Electric Dirt Bike Build series! In the last episode, I walked through the CAD design, frame geometry, and bench-tested the 10kW Golden Motor brushless motor and controller. If you missed that one, you can watch it here: https://youtu.be/m4eH-KG_7vU
In this video, I’m fabricating the tube chassis and rear suspension — bending, notching, and assembling the frame using 1" DOM tubing and my custom bike chassis jig for perfect alignment, and the Xphotonics X1 Pro laser welder to achieve deep, TIG-like welds.
What you’ll see in this episode:
🔹 Full-scale layout from CAD drawings for precision bends
🔹 Custom head tube & swingarm bearing housings
🔹 Compound angle tube bending and notching with 3D-printed templates
🔹 Progressive PDS rear shock linkage setup
🔹 Frame mock-up with wheels, forks, and chassis weight test (102 lbs so far!)
This bike uses a 10kW brushless motor with a two-stage chain drive and chromoly frame. The final build should come in around 200 lbs, combining lightweight construction with serious power.
In Episode 3, I’ll be finishing the motor mounts, controller, brakes, wiring, and getting the frame ready for paint or powder coating.
If you’d like to see how I built the frame jig, check the link below — free plans are available as well. I’ve also included links to the motor, controller, and welding equipment used in this build.
Thanks for watching! If you enjoy detailed fabrication content, hit LIKE, SUBSCRIBE, and turn on the notification bell to follow along as this custom electric dirt bike takes shape.
🔗 Links & Resources:
Episode 1 (CAD + motor test):
https://youtu.be/m4eH-KG_7vU
Frame jig build & free plans:
https://youtu.be/GpONBdvucc8
https://renewablesystemstechnology.com/project-blog/building-a-rotating-motorcycle-chassis-jig
Xphotonics X1 Pro laser welder:
https://youtu.be/12qQcygcBxI
📏 Specs:
Motor: Golden Motor HPM 10kW continuous / 20kWp dual stator PMSM
Controller: EZ-B72800 sinewave, 72V, 800A phase / 400A battery current
Transmission: 2-stage, 6.6:1 gear ratio, ~330Nm torque at the wheel
Battery: 72V lithium pack (planned ~4kWh, 100km range)
Suspension: 790mm adjustable forks + 330mm rear shock w/ progressive linkage
Wheels: 19” front & 18" rear, ~12” ground clearance
Target curb weight: ~190 lbs
Top speed: ~75 km/h
Golden Motor Products Featured:
HPM 10kW Dual Stator PMSM Motor
EZ-B72800 Sinewave Controller
Website: https://goldenmotor.bike/JAMESBIGGAR (use code JAMESBIGGAR to get 5% off)
#ElectricDirtBike #EVBuild #Fabrication #MotorcycleBuild #GoldenMotor #CustomChassis #LaserWelding #DIYMotorcycle #ElectricMotorcycle #MetalFabrication #3DPrinting #TubeBending #Welding #CNC
RST Website: https://www.resystech.com
Follow RST on Facebook:
https://www.facebook.com/RenewableSystemsTechnology
In this video, I’m fabricating the tube chassis and rear suspension — bending, notching, and assembling the frame using 1" DOM tubing and my custom bike chassis jig for perfect alignment, and the Xphotonics X1 Pro laser welder to achieve deep, TIG-like welds.
What you’ll see in this episode:
🔹 Full-scale layout from CAD drawings for precision bends
🔹 Custom head tube & swingarm bearing housings
🔹 Compound angle tube bending and notching with 3D-printed templates
🔹 Progressive PDS rear shock linkage setup
🔹 Frame mock-up with wheels, forks, and chassis weight test (102 lbs so far!)
This bike uses a 10kW brushless motor with a two-stage chain drive and chromoly frame. The final build should come in around 200 lbs, combining lightweight construction with serious power.
In Episode 3, I’ll be finishing the motor mounts, controller, brakes, wiring, and getting the frame ready for paint or powder coating.
If you’d like to see how I built the frame jig, check the link below — free plans are available as well. I’ve also included links to the motor, controller, and welding equipment used in this build.
Thanks for watching! If you enjoy detailed fabrication content, hit LIKE, SUBSCRIBE, and turn on the notification bell to follow along as this custom electric dirt bike takes shape.
🔗 Links & Resources:
Episode 1 (CAD + motor test):
https://youtu.be/m4eH-KG_7vU
Frame jig build & free plans:
https://youtu.be/GpONBdvucc8
https://renewablesystemstechnology.com/project-blog/building-a-rotating-motorcycle-chassis-jig
Xphotonics X1 Pro laser welder:
https://youtu.be/12qQcygcBxI
📏 Specs:
Motor: Golden Motor HPM 10kW continuous / 20kWp dual stator PMSM
Controller: EZ-B72800 sinewave, 72V, 800A phase / 400A battery current
Transmission: 2-stage, 6.6:1 gear ratio, ~330Nm torque at the wheel
Battery: 72V lithium pack (planned ~4kWh, 100km range)
Suspension: 790mm adjustable forks + 330mm rear shock w/ progressive linkage
Wheels: 19” front & 18" rear, ~12” ground clearance
Target curb weight: ~190 lbs
Top speed: ~75 km/h
Golden Motor Products Featured:
HPM 10kW Dual Stator PMSM Motor
EZ-B72800 Sinewave Controller
Website: https://goldenmotor.bike/JAMESBIGGAR (use code JAMESBIGGAR to get 5% off)
#ElectricDirtBike #EVBuild #Fabrication #MotorcycleBuild #GoldenMotor #CustomChassis #LaserWelding #DIYMotorcycle #ElectricMotorcycle #MetalFabrication #3DPrinting #TubeBending #Welding #CNC
RST Website: https://www.resystech.com
Follow RST on Facebook:
https://www.facebook.com/RenewableSystemsTechnology
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