How I built my own E-bike for 1/5 the cost of a buying new, and got a better bike in the process: A build series

Conception
I have been lusting after an E-bike(Electric assist) Bicycle for a long time, but could never really justify the cost of one as a toy, when I already had several bikes. The cheap ones are very heavy, and the nice ones can cost as much as a nice used car. It wasn't until several things came together for me that made it a reasonable project for me to pursue.

The Need
I work at a very large university, and parking is expensive, $1092.00 per year. It's also hard to find, and a pain because finding parking can make you late, and force you to walk a mile or two from parking to the office, if you leave campus for any reason during the day. In two words, it sucks.

I have been using a mixture of my car and public transit for several years, as the public transit costs are subsidized by my employer, (Half price at $528.00 per year) and I didn't have to spend as much money on the car for my 20 mile commute.

I also have a need for getting around campus for my duties, during the day, and I cannot drive, I average 5 miles a day walking on campus, I brought a 12-speed road bike I have to use when I want.

Circumstances change
About a year ago, I got a chance to move within 5 miles of the university. So now I walk about a mile to a bus stop, and that will get me to work in 20 minutes or so, but it's a walk straight uphill, and the buses are massively crowded 10 months a year with students. Think Tokyo subway packed. It's ok, but the uphill walk and bus ride, then another walk to the office make it a 45 minute commute many days. I try riding my bike in, but climbing a hill right from the start every morning is not good as I'm a gimp with a wrecked spine and a blown out knee. This calls for a different type of bike than what I own, really.

The Plan
Time to get down to specifics. I really did not want to spend more than $1200.00. I started pricing bikes and most of the new E bikes in my range went from utter crap mal-wart bikes with a motor tacked on the back and a lead acid battery. That was the $450-$800 range. And the $800-$1200 range got better, but was still dominated by low quality bikes with low quality components and a marginally better E drive added, all in the 500 watt hub motor style. And the bikes I liked? $3500-$7000!!! I was frustrated. So. what's an ape with 10 thumbs do when confronted with a problem? do the math and do it myself.

In my next installment, I will "do the math", and show the build in photographs, performed over the winter Solstice break, 2016.