Old School Marin Build

[billsy]

Thanks Knoxie.

I have a question for the collective. I've been thinking that it might be a good idea to rig up some kind of ebrake switch to at least one of my hydraulic brakes. I've read quite a bit on here about reed switches and the mounting thereof and couldn't help thinking there must be an easier option. So I've been scouring the net for a Pressure Switch that I can add to the hydraulic line of my brakes. The only two that I managed to find are linked below but they are meant for cars/motorbike so I assume the activation pressure will be too high and they will be a pig to integrate.

Has this been done before on an ebike?
Can anyone point me to a more suitable pressure switch or more user friendly electrical switch setup?

http://www.surpluscenter.com/item.asp?item=11-2400&catname=electric

http://helperformance.com/store/product_info.php?products_id=3158

Many thanks guys and please don't hesitate to coment on this one.

Chris

[billsy]

Its been a while since my last post, apologies for that but the odd spare hour I get these days has been spent on the bike which hasn't left much time for anything else.

Any who, the bike is pretty much finished and I have to say, it turned out WAYYY better than I thought it would. The ride is so smooth, the weight is perfectly placed, the acceleration is very good and the top speed is just where I expected it to be at 30mph.

I know I know you need pictures.

Here's the battery box trial fit just after welding. You can see the head's of three bolts inside the box. They are the type of fasteners you would use to join kitchen units together. I also added spacers between the two boxes these were cut from a length of Aluminium tubing. Oh and not forgetting Loctite…lots of Loctite. There's also two screws on top where the bottle holder would normally be





Here's a slightly more mature battery



Here's the triangle box I fabricated for the charger socket/fuse and main switch. The switch is also a 40 amp circuit breaker part number W31-X2M1G-40 the waterproof switch boot is a standard item.






Here's the finished bike. I just need to spray the controller mounting plate and sort out the DC-DC converter for the Magicshine.
What do you think?

[knoxie]

Looks great!! well done on getting it all finished, would love to see some videos of you whizzing about on it as well, be interested to know how the batteries perform as well, really tidy work on such a great bike as well, you should be well pleased!!

Knoxie

[billsy]

Thanks Knoxie

Yes I am well happy with it. Its really solid as well, can't wait to get it on some trails. The battery performs fine. I've used it every day this week for my commute which is 10 miles round trip which it manages flat out, no problem. I'm not sure exactly how much juice is being used as I'm having problems with the replacement Cycle Analyst (which Justin is addressing of course). I will try and get some vids up soon.

[knoxie]

Hi Billsy

Yes its a great looking machine mate and I know how well those bikes ride too so I bet you are having a blast, looking forward to seeing some videos of it on the move, it was cold today mind, i have been using my normal bike to get to work a I am trying to loose a bit of xmas weight gain! ha ha, weekend looks better, must dust the electric BMX down for a spin!!

I am sure that Justin will sort your meter issue, you have a BMS right? so at least your not going to drop your cells too low? thanks again for sharing the pictures, its one of the tidiest machines I have seen in ages!

Knoxie

[geoff57]

Hi
Just read through your build that's one mice job you done there.
I do have one thing to say about your batteries and BMS, you are using headways that have a high output on them but if I am not mistaken you are Using a ping BMS with them the BMS should be great for charging the headways I am putting a "48V" battery pack out of LiFePO4 from hobby king equally high output, with a ping BMS for charging the pack. Unless ping have made a radical improvement in how they make their BMS they will have a amp limiting circuit on the BMS Alongside the LVC circuit, this will probably limit you from getting the best out of your headways you may find that the BMS cuts power from the battery if you try to draw too many amps it ust to be 40A for the big 20aH packs ping made that may have improved now, if you do find that the pack is cutting out on you when you are drawing high amps say on a hill or at the traffic lights let me know.
I have an alternative way of using the batteries with a ping BMS, I have fitted 2 of my 8 channel LVC boards to my pack they work just like the LVC/HVC boars that gary sells but only have the LVC circuit I hope it will be ideal for use in your situation and for the test pack I have just finished building for my wife, you get the LVC protection you need when ridding the bike with the ease of charging that a ping BMS gives you.
You would need 2 of my boards plus probably 4 silicone covered balance wires I am bound to have them in stock.
See if the setup you have gives the amperage output you want and so the speed you want if not and you want mor power than the ping BMS will give you come have a word with me I willshow you how to take the amperage limit out of the ping BMS equation.

Geoff

[billsy]

Hi Geoff

Thanks for your comments and suggestion's. The Ping BMS I'm using is the high rate version. IIRC it is good for 60A continuous and upto 100A for a couple of seconds. I think it should be fine.

Where abouts in Blighty are you Geoff?

Thanks again

Chris

[geoff57]

Hi Geoff

Thanks for your comments and suggestion's. The Ping BMS I'm using is the high rate version. IIRC it is good for 60A continuous and upto 100A for a couple of seconds. I think it should be fine.

Where abouts in Blighty are you Geoff?

Thanks again

Chris

Hi
Yes that BMS looks like it will do the job my last ping battery was several years ago and things have progressed for the better since then, my idea is still good for those out there that started with a ping a few years ago and their BMS survived when the cells would not hold a charge, this is what I have done I did not buy a new one just new cells.
I'm in Nottinghamshire about 250 miles from you, but if I book in advance about £30 away on the train with my train folder for decimate and my mountain folder if I am lucky.

Geoff

[billsy]

I put some 'Marzocchi Drop Off Triple' forks on the bike at the weekend. I'm well happy with them. However, went for a test ride, ended up on a road I havnt been down before and hit an object in the road and ruined the rear rim
So I could do with a little help if possible, I need to find an identical rim so that I can re-use the spokes that 9C supplied. Typicaly this rim (Samson Champion) is impossible to find in the Uk so I'm looking for a 26" rim with a cross section height of 25mm. I think this is the same as a ERD of 530. Can anyone sugest a rim that meets this criteria? I am in hospital waiting to have a shoulder op as i type and so will have plenty of time to ponder my options but won't be touching the bike for several weeks.

Cheers Chris

[chroot]

HI-

Your ebike is great!! You might want contact Johnrobholmes for the highly quality rim and spokes. I learned from GCinDC's review on his new rear rim and spokes. he sent his 9C motor to Johnrobholmes and He put best high quality rim and spokes and GCinDC tested stress and abuse on new rim showed high strength and stronger!! Excellent service

Here the link you might want check. [viewtopic.php?f=31&t=16218

[billsy]

HI-

Your ebike is great!! You might want contact Johnrobholmes for the highly quality rim and spokes. I learned from GCinDC's review on his new rear rim and spokes. he sent his 9C motor to Johnrobholmes and He put best high quality rim and spokes and GCinDC tested stress and abuse on new rim showed high strength and stronger!! Excellent service

Here the link you might want check. [url=http://endless-sphere.com/forums/viewtopic.php?f=31&t=16218][viewtopic.php?f=31&t=16218/url]

Thanks Chroot I have sent him a PM.

[chroot]

Welcome, I plan have him replace stronger rim and spokes when I have enough money to buy a xlyte x5303 hub motor and I would rather have everything beef up to handle the nasty monstrous torque and speed demon by xlyte x5303.

I just killed my 9C 9x7 hub motor *sighs*

Your battery box hang on top on the frame. It gives you great balance and this similar Rebelpilot's ebike. It made me want relocation my 20s2p to front as similar yours.

keep it up!


PS. I see you upgrade full length front suspension fork. I am curious how much cost the full length suspension fork and I seems cant find these full length fork anywhere. Is your full suspension comfortable like plush soak the bumps?

[billsy]

Welcome, I plan have him replace stronger rim and spokes when I have enough money to buy a xlyte x5303 hub motor and I would rather have everything beef up to handle the nasty monstrous torque and speed demon by xlyte x5303.

I just killed my 9C 9x7 hub motor *sighs*

Your battery box hang on top on the frame. It gives you great balance and this similar Rebelpilot's ebike. It made me want relocation my 20s2p to front as similar yours.

keep it up!


PS. I see you upgrade full length front suspension fork. I am curious how much cost the full length suspension fork and I seems cant find these full length fork anywhere. Is your full suspension comfortable like plush soak the bumps?

The new forks are amazing actually. They soak up the bumps really well. Problem is, the rear shock (Fox Float RL) now feels a bit cheapo in comparison. I paid £125 ($200) on ebay. They are in great condition. I managed to find a used DH wheel with 20mm thru axle hub to suit the forks for £15 from a local shop so I'm well happy.

What happened to your 9C hub?

[chroot]

That's cheap you got excellent 200mm travel suspension fork and I gotta start hunt similar your fork for my MTB.

Killed 9C hub motor, I really don't know how did the 9C hub motor died and I even tested volt meter each wires I.E. throttle, controller, ebrake, hall sensor and phase wires. It seems show just fine and I am in process sending my 9C hub motor to Edward Lyen to inspection and repair my 9C hub motor.

In meantime, I ordered 10H aka ampedbikes DD hub motor thru Terry at Hightekbike, The 10H gives little beef up than old version 9C hub motor and they should be here sometime by next monday. Once 10H gets here and same time send my 9C to Edward Lyen to inspection and repair.

Perfect timing for me give a review on 10H hub motor vs 9C hub motor comparison.

I spoke with Danny Ray at ampedbikes to get the tech info difference between 9C and 10H. Here his comment.

We actually designed the 9C 9x7 windings in 2007.( It was actually Jerry one of our local dealers that designs brush-less motors for RC airplanes) We worked with 9C at the time and they only had the 8x8 windings available as they mostly sold in Europe.

We have re-designed the our DD motor 3 times since then.

1. We are using 9x7 windings.
2. We increased the thickness of the internal wiring. (this allows for higher voltages and higher torque due to no heat loss)
3. We use higher end hall sensors.
4. We changed the outer ring that holds the magnets from aluminum to steel. (this gives us about 5% more torque and 5% easier freewheeling)
5. We changed the thickness of the spokes as well as the way they are laced..
6. We redesigned all kits to have the ability to install ISO standard disk brakes (simply swap yours over from your rim)
7. We centered the axle so that dishing is no longer required.

Overall it weighs about 1/2 lb heavier.

Thank you for contacting us!.
Danny L. Ray II
http://www.AmpedBikes.com

[billsy]

Sounds like you've had a nightmare with your 9C. Hope you have better luck with the 10h it sounds like that bad boy should stand up to some abuse.

Cheers

[gwhy!]

Hi Billsy,
un-lucky about your rim mate. I have had a quick look on tartbikes and the only rim that I could see that is remotely close to ERD of 530 is a EDR of 532 and that is one hell of a wide rim as well 4.2cm!, tartybikes do a very good range of ( sizes ) a very good quality spoke ( may be worth going for a different rim ) . I also like the forks you have now as well , I have managed to get a nice set of tripples for my bike now also . I also bought a, what have turned out to be a very nice rear shock ( for my new FS build ) new from a supplier £34.00 +pp , a absolute bargain (190mm i2i) , its not the lightest shock but do appear very strong and well made and fully adjustable as well ( very smooth and progressive ).

Good luck with the op.

[billsy]

Hi Billsy,
un-lucky about your rim mate. I have had a quick look on tartbikes and the only rim that I could see that is remotely close to ERD of 530 is a EDR of 532 and that is one hell of a wide rim as well 4.2cm!, tartybikes do a very good range of ( sizes ) a very good quality spoke ( may be worth going for a different rim ) . I also like the forks you have now as well , I have managed to get a nice set of tripples for my bike now also . I also bought a, what have turned out to be a very nice rear shock ( for my new FS build ) new from a supplier £34.00 +pp , a absolute bargain (190mm i2i) , its not the lightest shock but do appear very strong and well made and fully adjustable as well ( very smooth and progressive ).

Good luck with the op.

The op went well thanks Kevin. Just got to keep the sling on for at least four weeks which is a bit sh1t.
Thanks for the Tartybikes heads up, they got some very nice stuff. I did manage to find an almost identical rim that is sold by various companies in the UK. It’s a Rigida Matrixx. I now I now, it’s a cheapo rim but the bike will mainly be used for commuting so should be good enough. I am assured that the 36 hole pattern is evenly spaced even though the images on every web site I've seen it on show a grouped pattern. I also ordered some chainsaw files in case I need to file out the eyelets (thanks Ypedal).
 
What forks did you end up with? Also have you got more info for the rear shock or a link?

Cheers

Chris

[gwhy!]

The op went well thanks Kevin. Just got to keep the sling on for at least four weeks which is a bit sh1t.
Thanks for the Tartybikes heads up, they got some very nice stuff. I did manage to find an almost identical rim that is sold by various companies in the UK. It’s a Rigida Matrixx. I now I now, it’s a cheapo rim but the bike will mainly be used for commuting so should be good enough. I am assured that the 36 hole pattern is evenly spaced even though the images on every web site I've seen it on show a grouped pattern. I also ordered some chainsaw files in case I need to file out the eyelets (thanks Ypedal).
 
What forks did you end up with? Also have you got more info for the rear shock or a link?

Cheers

Chris

Hi Chris, Im pleased the op went well and 4 weeks will fly past ( weather will be better, lighter evenings and warmer .. Riding weather ) .

I managed to get what is called strata front forks, they have 35mm stantions and are built like a brick sh!thouse ( but one leg is leaking ) I know very little about push-bike suspension components to be honest ( being a motorcycle person ) but I dont think these forks will let me down and they do feel very smooth with a lot of travel ( even thou they are about 20 years old ) , the trees have a small crack but I have a replacement set of trees that fit so all is good , the rear shock that I have, is called a tough shock FDR http://www.apro-tek.com/ss/WEB/images/FDR.htm it appears to be a copy of the fox shock , and as long as the seals hold up I am well happy ( I was looking for a coil over oil shock, these seem to be getting pretty rare ) a air shock will be now where near upto the abuse that I intend to put it through but only time will tell as to the whole suspenssion setup that I now have to how well it lasts ( The whole lot front and rear with spare trees all came to just under £100 ). I got the rear shock from a ebay seller 7diamondmd He do not continually list these shocks but I think he must list them as he gets them, he also sells another make ( but I cant remember what it is off hand ) which was £3 cheaper but they did look identical.

[D-Man]

Looks good. How much does that Ping BMS cost?

[billsy]

Looks good. How much does that Ping BMS cost?

D-Man the Ping high rate BMS was $72 direct from ping.

Cheers

[billsy]

I'm definitely feeling a tugging to attend the Great Commission School this upcoming summer of 2012. I'm curious, will it be module 3?

Ex squeeze me? Baking powder?

[billsy]

Thanks Knoxie.

I have a question for the collective. I've been thinking that it might be a good idea to rig up some kind of ebrake switch to at least one of my hydraulic brakes. I've read quite a bit on here about reed switches and the mounting thereof and couldn't help thinking there must be an easier option. So I've been scouring the net for a Pressure Switch that I can add to the hydraulic line of my brakes. The only two that I managed to find are linked below but they are meant for cars/motorbike so I assume the activation pressure will be too high and they will be a pig to integrate.

Has this been done before on an ebike?
Can anyone point me to a more suitable pressure switch or more user friendly electrical switch setup?

http://www.surpluscenter.com/item.asp?item=11-2400&catname=electric

http://helperformance.com/store/product_info.php?products_id=3158

Many thanks guys and please don't hesitate to coment on this one.

Chris

Thought I'd do a little update on the above question. It turns out that there is an eBike version of the very brakes that I'm using on the Marin. They are called "Tektro Auriga E-Sub". According to the Tektro site, they are OEM only but a quick Google finds them for CAD$110 not to bad

http://www.tektro.com/_english/01_products/01_prodetail.php?pid=131&sortname=Disc&sort=1&fid=1

http://cyclepath.ca/shop/product_info.p ... 1cee582b6a

Also here http://ebikessf.com/tektro-ecomp

I Also just stumbled across this post which discusses a pressure switch that can be added to existing hoses
http://endless-sphere.com/forums/viewtopic.php?f=2&t=30376&p=446570#p446570

[BATFINK]

That brake switch looks great. Just what I need. Can you buy jut the brake lever or switch on its own and connect it to any hydraulic brake line as it looks like that is the price for the whole brake set?

Sent using Endless-Sphere Mobile app

[billsy]

That brake switch looks great. Just what I need. Can you buy jut the brake lever or switch on its own and connect it to any hydraulic brake line as it looks like that is the price for the whole brake set?

Sent using Endless-Sphere Mobile app

I would imagine the lever and calliper are supplied plumbed together. It'd be worth dropping them a line tho. However if you are just buying the lever this will mean you'll be plumbing it in, in which case you may as well just buy the in-line sensor/switch and plumb that in.

Cheers

[Brentis]

Just fabulous work there.
I missed most of this thread.
Before I worked up the courage to post I guess )

Of particular beauty to me are

Billys' TorqueArmFitted1.jpg (61.36 KiB) Viewed 384 times

Billsy' Side saddle battery EX..jpg (95.39 KiB) Viewed 384 times

Top job.

Enjoy.