Electric KTM 65 SX

Goal:

The goal of this project was to build a similarly sized, and still portable bike to the previous projects, but also with a massive step up in frame design, build quality and suspension. Instead of heavily upgrading a kid's toy frame, starting with a name-brand frame was not only much more durable, but also much cheaper than upgrading a kid's toy frame. The purpose of this bike was to also create a much more capable bike for trail riding and actual off road use while still being in a small, portable and light package.

How:

I bought a KTM 65sx with a seized engine, removed the engine and stripped the frame the school parking lot one day before work. Then I 3D scanned the frame to make designing the powertrain swap much easier. The project sat for a couple months until we were forecasted to get a lot of snow, and I realized none of my vehicles could deal with deep enough snow, so I decided to build the bike in about 5 days before the storm. I designed, waterjet, and TIG welded together the motor mount, battery mount and sprocket. They were all designed out of flat sheets with notched edges to easily lock together for welding. The scans helped align the chain and guide drive sprocket location as well. A headlight and low voltage system were added as it was dark by the time I was able to ride. 

Takeaways:

With a 3D scanner, and access to a waterjet and TIG welder, as well as a lot of past experience building multiple electric vehicles with similar powertrains, it was very fun to see the whole project come together on such a short timeline 

About:

Time: January 20-23 2026 for the powertrain

Skills: 

Fabrication: 3D scanning, Waterjet, TIG welding, 3D printing, soldering

Software: Fusion 360 (design and FEA)

Stats:

Motor: 14Kw+ Kunray KR5V

Battery: 60v 24Ah currently, 72v 20Ah custom built battery soon

Controller: Fardriver 72450, 195A line, 350A phase

Speed: 55mph+

Range: 35+ miles

Weight: 125lbs