Ebike Project 72V HS3540 UK "build thread" +Videos!

[rui_fujino]

I've been away over the weekend and didn't get to ride it due to something went wrong with my motor and it started to make vibrating sound and no power...I suspected water got into halls connectors while its been snowing.
I've checked all and finally when I was about to give up I saw this...

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Rusting 5pin connector

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they are suppose to be waterproof as well as that, I put so many layers of heat shrink and all....I've cleaned them up and now its back and running

On other news, I couldn't figure out what went wrong with my BMS Charger 2 so I've decided to transplant broken parts from charger 2 to 1 and see if I can get one of them working...

[rui_fujino]

Its been quite a while since my last post but yet again, I made silly mistake...I accidentally shorted my battery for the second time. (Never charge when ur tired). I've checked the cells and they look fine (thank god!)
I haven't had time to make any upgrade or add switches but I'll do them soon.

Interesting news: my from speedometer has gone crazy when I hit 58mph going down the hill and it think it did 90mph!!

90mph?!?!

[rui_fujino]

Last night I took my shorted connectors and replaced with new sets and here is what I saw...

After KFF

I never thought those massive connectors could melt...

[BATFINK]

Nightmare Rio, electricity can melt a lot of things, I remember taking a factory apart and as I was disconnecting a wire from a live socket (some idiot was supposed to have shut it down) there was a big blue flash and the electricity melted the screwdriver, it actually cut the end clean off!!!

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[BATFINK]

Sorry I meant Rui

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[electr0n]

How did that happen to your connectors? Did positive touch negative?

[rui_fujino]

How did that happen to your connectors? Did positive touch negative?

I was balance charging four sets of 5s2p and I've accidentally plunged battery and battery together instead of battery to the charger.

[rui_fujino]

Its been a LOOONG time since I updated! so here is whats going on!
My laptop died(7years old) so I decided to clean it up and upgrade to new HDD plus installed ubuntu(no virus) ...then I've got my self chain cleaning tool from ebay>>>
http://www.finishlineusa.com/products/chain-cleaner.htm
It is super effective! I really do recommend you guys to get this

Here is state on my ebike>

Clean bike!

Currently no change other than cleaner chain, disk brakes and a new side mirror
I do recommend using "white lightning Clean Streak" it removes all the dirt/oil/lube with strong degreaser spray and at the same time the liquid evapurates so no need to wipe them after! disk is now soo much stronger without squeaking! i've used it for chain cleaning as well!

Almost forgot, BMSBattery are doing sale at moment any all the charger has reduced price! since I am still struggling to fix mine I've got myself 400w charger for only $40!!

[Trackman417]

Looks good! However one thing that is concerning me ought now is where u placed ur lock. I mean sure it's a good place to put it, but if it some how gets caught in the spokes and you are at speed, you could get thrown off the handlebars.
I hope this helps!

[rui_fujino]

Looks good! However one thing that is concerning me ought now is where u placed ur lock. I mean sure it's a good place to put it, but if it some how gets caught in the spokes and you are at speed, you could get thrown off the handlebars.
I hope this helps!

Hahahaha funny how ur the first person to mention that , I've actually already had this problem but what happened was my lock just got ripped off the mount and nothing was seriously damaged but If you can think of better placement I would love to hear about it!

[Trackman417]

How about rotating it so the lock is facing the other way? So when it bounces into the spokes the spokes will spit the cables out.

[rui_fujino]

Finally, I bought another BMS charger (this time is 400w) cos it was cheap....I can finally charge bulk again!
I didnt notice before but 400w charger is inch smaller than 600w ones...which is quite handy for the size!

BMS Charger

Also another good news, Doc's torque plates has arrived so i can now officially use regen setting on my bike!

Doc's torque arms

[rui_fujino]

Bad news...Yet again by BMS charger let me down charged my battery half way and capacitor seem to have blown up
Im going to make the complain and might as well try nd replace the cap...but I think from now on i'll use Original KP charger fromhttp://www.evassemble.com they are better quality then BMSbattery so if anyone planning to get them...DONT!

Edit:
here is the picture of what seems to have gone wrong...

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[Trackman417]

Yeah I think you should stop buying chargers from BMS lol
Just my $.02

[rui_fujino]

Yeah I think you should stop buying chargers from BMS lol
Just my $.02

well I agree with you on that. but since my complaint seem to have gone through. they told me they'll send me a new one asap!
But then I didnt want 400w so I asked them if you could send me a 600w ones..then they said no problem! So! I will wait and see how that'll treat me...

I have looked around for alternative ones and I think this is the best you can buy!
http://www.evassemble.com/index.php?main_page=index&cPath=3&sort=20a&page=2
Ev assemble looks like the original source of alloy shell but they are much better and they do offer warranties

[pchen92]

Did you modify the charger so it can charge your lipo up to 4,15V/cell ? Or do you use it @ 83,6V ?
Thanks

[rui_fujino]

Did you modify the charger so it can charge your lipo up to 4,15V/cell ? Or do you use it @ 83,6V ?
Thanks

I didnt make any modification so yes they are just charge to 83.6v...but in case your wondering about the individual cell then I've got battery medics to balance them while bulk charging

[pchen92]

And you plug the battery medic everytime you use the batteries ? ie when charging and discharging them ?
How many of them are you using ? 4 ?
What's your range ?

thanks

[rui_fujino]

And you plug the battery medic everytime you use the batteries ? ie when charging and discharging them ?
How many of them are you using ? 4 ?
What's your range ?

thanks

yea i use them once in few charges not all the time. ( I've never discharged my batteries lol)
yea i've got 4 of them so that i use one per 5s2p.
I've got 10Ah but I use only 8Ah, since I pedal quite alot and I dont go WOT so i get range of about 20~30miles

[pchen92]

Ok thanks you. I'm gonna make a Giant DH Team w/ HS3540 @ 74V 45A (max but in town I'll set it to 25-30A) w/ 20S2P of lipo on a 24" wheel.

[rui_fujino]

got little update today! I've finally decided to upgrade my rear disc brake to 185mm! it feels so much better!

185mm Avid G2CS

also since I had taken out the rear wheel off I've decided to clean it So far, my speedometer tells me I've done + 500miles and no problem!
I was worried about the Nord-lock and my cheap torque arms but they are holding on well. No damage on both axle and drop-out

also, I had little more time so I've taken picture of all the things I have as a spare...quite a lot lol i believe 2 spare motors, 3x BMS bulk chargers (dead), 3 controllers and 52v lifepo4 battery...etc :p

my junk yard

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Oh, also I finally decided to weigh my bike! and OMG! it weighs like 35kg! heavier than i thought...
I've been thinking of upgrading my headlight soon and I want to use CA to provide the power to it....anyone got good cheap idea which are as good as Cycle Lumenator?

[rui_fujino]

little update here.
Good news is that BMSbattery guys are sending me a new 600w alloy shell for free But no double it'll blow up soon...
Bad news...I believe my new 185mm Avid G2CS is little warped and cant quite get it right...
oh and i've fixed on/off master switch to FalconEV bag which is great!

[rui_fujino]

I've made more upgrades in last few days.
I've upgraded to Doc's torque arm on one side and I've glued my original torque arms together to make one thicker torque arm to apply on the opposite side of the drop out. (I didn’t like the Doc's torque arm with derailleur since I wasn’t sure if it works well with my setup.)
I've also programmed my controller to do regen so i'll inform you guys with how much regen i got from fully charged battery!
i'll upload some more pics tomorrow with all my setups. I've decided to power my headlight from the CA so got few things from china coming sooN!

[rui_fujino]

little more updates.
I have been meaning to add the light switch and horn/controller switch to the handle bar but the one I got from ebay came with side signal switch which looked useless for me so i've customised it to look like this!

the original (replaced horn button to On/Off switch)

customised switch

I've replaced the signal switch to 3way switch which allows me to change the power setting of the controller from 30%, 60% and 100% (I've been using it with 30% 100%120% but I've realised I dont really need to use 120% at all...)
Some point this week, My 12~94v ebay light will arrive so hopefully I'll be able to attach the light switch to this as well!

PS: since i've added regen setting on, I hardly need to use brake! I guess i didnt really needed to upgrade the rear disc brake...lol It does feel great having regen on tho, so far, I'm getting about 5% of battery back! i'll update all the stats when my battery is empty!

[rui_fujino]

My ebay headlight has arrived I've tested with 52v and OMG they are sooo bright
the light i've got can take upto 90v so i'm planning to feed it with my CA so keep the wires looking neat
I'll have to come up with good mount but it's looking very good!
Also I've bought ebay VDR and hoping to get some London riding videos going soon!

disassembled light