full suspension KHS+GNG+konion= :mrgreen:

With no shop space and no options for getting any in the near future I thought I might have a go with something a little less custom and a whole lot less power. Seeing all the really cool GNG builds has inspired me to go the same direction, so I kept a keen eye on CL for a decent full suspension bike and sure enough a 2004 KHS FXT comp turned up in providence for $325 so I jumped on it. Since then I have spent most of the time mocking up a nifty battery enclosure and what I came up with was something big enough to throw in 15ah@48v worth of makita cells I bought from the good doctor.










I'm thinking aluminum for the enclosure that will be strapped on so it will be easy to remove and charge/store indoors.

I'm also looking to mount the controller almost directly the the gng bracket so I can keep the front fender and easily cover all the components that would not prefer to be covered with water, salt and mud.

I have a battery box mounted like that. I have found that when you are using your bike for trail riding, the frame flexes munches on the box. I have a wooden box, so mine cracks and groans.My far superior battery bay is this one here: http://www.endless-sphere.com/forums/viewtopic.php?f=3&t=44740 If you decide to go for a box build consider having a rubber barrier between box and bike frame.

GNG kits are pretty awesome; they can climb up anything and not overheat, and it's super handy to be able to pop a wheelie with the flick of a throttle. It lets you hop up onto boulders and things. GNGs have a big problem however in that the tensioner for the belt doesn't adjust. Your kit will run great until the belt stretches a little, then the thing starts slipping.

Bhzwindtalker and Christerljung are converting theirs to chain drives. I personally think the belt drive can work with a better tensioner setup and I plan to fix mine by pinching the belt tighter with a modified c-clamp with roller blade bearings pushing against the belt. I have everything welded up, and it's looking good, I just need to mount it and try it out.

I think your battery choice, bike choice, and decision to make the bay removable all sound great.

Good luck with your build.

Jared

good tip, I didn't think the frame flexed that much. maybe leather might work in that regard as well.

Parajared said:

GNGs have a big problem however in that the tensioner for the belt doesn't adjust. Your kit will run great until the belt stretches a little, then the thing starts slipping.

Click to expand...

But they do adjust. Where the tensioner arm is attached it has an oval hole. Then, on each side of the tensioner arm there is a little tab that sticks out. I think you could make a little spanner that would help, but I just used two flat blade screw drivers to keep the belt tensioned while tightening the screw.

It was just going to be too cramped in the frame of the KHS for all that battery, so I took a page from the 'ol 4X4 PVC fencepost playbook and put the battery case over the top tube.








I used a chunk of the 6X6 fencepost to craft a nifty motor cover that doubles as a controller mount and protector. This really made it plain how easy this material is to work with, all you really need is a dremel and a heat gun and you're good.







this thing is ready to go for the most part, it is all wired up and only needs a battery to make it go. Let's just say I'm getting what I can only assume is the usual lessons one learns with their first foray into the wide world of DIY cell salvage and pack building.