Converting a classic motorcycle into an electric marvel presents numerous challenges. While sourcing the right drivetrain and fitting it into a chassis designed for an internal combustion engine are significant hurdles, the true art lies in preserving the bike’s vintage charm. In this article, we explore Danny Mantyla’s exceptional electric conversion of a 1967 Honda CA160 Dream, showcasing how he managed to enhance its aesthetics.
The Quest Begins
Danny Mantyla, an amateur bike builder, embarked on this journey when a conversation with his wife sparked an idea. She preferred the classic Honda CA160 but in black. Fate led Danny to discover a black Honda CA160 on Craigslist, which he purchased for $500 the very next day.
Perfect Fit for His Wife
The CA160 Dream had been dormant in a barn for a decade, with a seized engine and a frame designed for concealing wires—an ideal canvas for an electric conversion. Beyond the technical challenges, Danny had a specific motive for the transformation. He wanted his wife to share in his motorcycle passion, but she lacked the desire to learn manual transmission. Additionally, she had a strong aversion to gasoline smells and noisy motorcycles, making an electric bike the perfect solution.
Crafting the Electric Heart
Danny pieced together a 72v system featuring a 4kW hub motor from QS Motors and a controller from Kelly Controls. For the battery, he innovatively constructed his own pack using up-cycled LG Chem pouch cells. However, what truly stands out is his meticulous assembly process.
Preserving Vintage Aesthetics
Danny’s appreciation for the Dream’s swooping frame and curvaceous fenders guided his design philosophy. He envisioned what a 1960s-era Honda electric motorcycle might look like and used this as his guiding principle in creating the battery enclosure—a teardrop-shaped masterpiece. This enclosure, with intricate detailing added using a bead roller, seamlessly integrates into the Dream’s frame, appearing as if it were factory-original. Remarkably, it can be easily split in half for battery access.
Integrating Electronics
The controller found its home within the frame’s recessed section, once occupied by the old lead-acid battery. On the other side of the frame, an old chrome clutch cover took on a new role as an access point for the controller’s wiring. Danny ingeniously incorporated a DC-to-DC converter into the old fuel tank, along with an analog charge meter, power switch, and indicator light. While it’s common to transform an old filler cap into a charge port in electric vehicle conversions, the Dream’s narrow filler neck required a unique solution, resulting in the charge port discreetly residing on the back of the battery case.
Preserving Classic Features
Danny ensured that the Dream retained its vintage charm by restoring the OEM headlight bucket and glass, outfitting them with modern LED internals. Additional controls remained true to the era, with the addition of a handlebar kill switch. The solo seat was sourced from a local swap meet, and an antique store yielded the luggage rack.
Performance and Pleasure
Although the electric conversion modestly affects performance, the primary objective was not speed or range. With a top speed of approximately 55 mph, slightly below the CA160’s original 68 mph, and batteries at 66% of their original capacity, the practical range is around 20 miles. Nonetheless, Danny describes riding the Dream as an immensely enjoyable experience, likening it to a self-propelled heavy bicycle, smooth and silent.
A Stealthy Gem
One of the most delightful aspects of Danny’s creation is how it deceives those unfamiliar with motorcycles. To the untrained eye, it appears as a beautifully restored classic motorcycle, completely concealing its lack of a gasoline engine.
Performance Metrics:
- Top Speed: 55 mph (88 kph)
- As Planned: Danny’s expectations for the top speed were met precisely.
- Range: 20 miles (32 kilometers)
- Accurate Estimate: The estimated range aligned perfectly with the actual result, considering regen braking was not activated.
- Potential Improvement: With new batteries, the range could likely be extended to 30 to 35 miles.
- Charge Time: Approximately 5 hours (Estimated)
- Small Charger: Danny currently employs a tiny 3-amp charger, drawing energy equivalent to two 100-watt incandescent light bulbs.
- Possible Upgrade: While an upgrade to a 5, 6, or even 10-amp charger is possible, caution is warranted, as a 10-amp charger might exceed the battery enclosure’s fuse capacity.
Image Source: Honda CA160 Dream electric conversion by Danny Mantyla
