What is the most difficult? part of converting a classic motorcycle into electricity? You might think it’s sourcing a suitable powertrain or fitting it into a chassis designed for internal combustion engines. Sure, those are all notable challenges — but the real trick is to get it done without spoiling the bike’s classic aesthetic.
Amateur bike builder Danny Mantyla figured it all out. He just traded in this 1967 Honda CA160 Dream for an electric motor swap. And he did it so well, that it looked even cooler than before.
“One night I showed my wife pictures of a red Yamaha XS650 and a red Honda CA160,” Danny told us, “and I asked her which one she liked best. She says the Honda, but only if it’s black. That night I woke up in my sleep and started looking at Craigslist for no particular reason.”
“And then I found it! A black Honda CA160. I bought it the very next day for $500.”
Thanks to sitting in the barn for decades, the engine of the Dream was completely confiscated. A broken motor and a well-stamped frame to hide the wires, are good components for a power adapter. But Danny has more than one reason to swap.
“I wanted my wife to be able to ride a motorcycle next to me, but she didn’t know or didn’t want to learn how to use a manual transmission,” he explains. “She is also really sensitive to the smell of gasoline and exhaust, and she hates noisy motorcycles with burning passion. So this e-bike is a great fit for her.”
Danny assembled a 72v system, using a 4kW hub motor from QS Motors and a controller from Kelly Controls. As for the battery, he built his own pack from recycled, used LG Chem bag cells. But it’s the way he puts it all together that is truly impressive.
When the Honda Dream was stripped bare and placed on the table, Danny was captivated by the swooping silhouette of the sculptural frame and rounded fenders. So he knows that whatever he adds needs to complement that, not against it.
“If Honda made an electric motorcycle in the 1960s,” Danny asked, “what would it look like? This was the design goal when building the battery case.”
With that in mind, he built a teardrop-shaped cover that uses a bead roller to add some character. A testament to Rob’s creativity and metalworking skills, it sits within the Dream’s frame as if it came from the factory. And it can be split in half in a flash, should you need access to the battery pack.
The controller is mounted directly into the recess of the chassis, where an old lead-acid battery is used. On the other side of the frame, a discarded chrome clutch cover has been repurposed as an access point for the controller’s wiring.
Danny fitted a DC-to-DC converter into the old gas tank, then fitted an analog charge meter, power switch, and top indicator light. It’s a traditional EV conversion trick to turn the old filler cap into a charging port — but the Dream’s filler neck is too narrow for this. So instead, the charging port is hidden on the back of the battery case.
The Honda OEM headlight box and glass have been restored, then fitted with additional LED lights inside. There’s also an off switch on the handlebars, but the rest of the controls look appropriately vintage. Danny got his seat alone from a local swap, and he found a luggage rack at an antiques store.
As for performance, it’s modest at best—but going fast or going far isn’t the goal here. Top speed is around 55 mph, slightly below the CA160’s original 68 mph top speed. And since the recycled battery has only about 66% of its original capacity left, the real-world range is about 20 miles.
However, Danny said it was fun to ride. “It’s so smooth and silent, it’s really like a really heavy bike that can magically propel itself. Riding it just brought a smile on my face, it was a very enjoyable experience.”
“My favorite thing is when someone sees it – someone who knows nothing about motorcycles – and they just look at it and see a beautifully restored, but otherwise very ordinary, vintage motorcycle. . They didn’t even realize it didn’t have a gasoline engine.”
Go danny’s website for details on his electric Honda Dream, including costs.
