My first eBike build: DH 2WD in China

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shenzhen_ex   100 W

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My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 05 2013 6:31am

For the last 2 months I have been piecing this eBike together from Taobao with some fabrication required. I decided to go with 2WD. I asked for advise here on E.S. for a few of the details along the way and the response has been unbelievably helpful.

This is going to be an awesome hobby!

I ordered a 48v 20ah A123 battery pack today. Hope this thing runs.

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Dual controller housing
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DSC_6785.jpg
20mm through axle adapter & TA
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DSC_6784.jpg
150mm dropout adapter & precision wire-cut TA
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Capture.JPG
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bars.JPG
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Last edited by shenzhen_ex on Aug 10 2013 1:05pm, edited 7 times in total.

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spinningmagnets   100 GW

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Re: My first eBike build: DH 2WD in China

Post by spinningmagnets » Aug 05 2013 8:27am

Welcome to ES! Your E-bike is very well done.

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 05 2013 8:59am

spinningmagnets wrote:Welcome to ES! Your E-bike is very well done.
Thanks spinning.

I have mixed feelings about finishing my E-Bike. For the past 2 months I have had something to design, something to build, and a ton of meaningful research to do on-line to get this build done. I really want to build another E-bike after I get this one running well.

The LBS here has a recumbent that he doesn't know what to do with. I was thinking that if I put 3-5 flags on the back, spread out like peacock tail feathers, that it might be safe to ride an E-recumbent in China.

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teklektik   10 GW

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Re: My first eBike build: DH 2WD in China

Post by teklektik » Aug 05 2013 9:32am

I've seen some shots of your battery mount in other posts - maybe you could re-post shots here and describe how the box mounts up and is held in place...
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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 05 2013 10:02am

teklektik wrote:I've seen some shots of your battery mount in other posts - maybe you could re-post shots here and describe how the box mounts up and is held in place...
teklektik, Thanks for asking. My battery box is way over designed but at least I wont have ever to worry about it flying off :oops: .

I think the images describe how it works better than words.

If you look closely at the first image in this thread you can see the small holes where a pin captures the box mounted blocks to the fork stanchion mounted blocks.

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removable bat box.JPG
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cassschr1   10 kW

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Re: My first eBike build: DH 2WD in China

Post by cassschr1 » Aug 05 2013 9:23pm

Man thats nice. Very interested in the hill climbing ability of this bike. Will be watching.

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 05 2013 9:44pm

cassschr1 wrote:Man thats nice. Very interested in the hill climbing ability of this bike. Will be watching.
Thanks cassschr1....But I have no Idea how this this E-Bike will climb yet. I should know this weekend after my battery arrives. I will post the results.

It has 24" rims.

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Re: My first eBike build: DH 2WD in China

Post by sk8norcal » Aug 06 2013 1:06am

cool, subscribe.

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 06 2013 8:16am

sk8norcal wrote:cool, subscribe.
Thanks sk8! I will let you know how it runs.

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Re: My first eBike build: DH 2WD in China

Post by mattrb » Aug 06 2013 9:57am

Amazing bike!
52v Crystalyte 4060 Phasor and 4000w Cyclone Elite

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 07 2013 8:53am

mattrb wrote:Amazing bike!
Thank's Mattrb, your comment means a ton. Chinese people are calling me "insane" for this build.

I see that you are also new here. This forum is an amazing resource for noobs, I am just a bit concerned that the old time members here don't remember what it was like to know nothing about eBikes ( BTW, I speak for myself).

Below: A pic of my 3rd kill switch. Kill switch # 1 is way out of focus in the lower right corner.
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3rd kill switch
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sk8norcal   100 MW

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Re: My first eBike build: DH 2WD in China

Post by sk8norcal » Aug 07 2013 10:56am

hey shenzhen-ex,
when you are done, you should let this guy try it,
a vblogger that i follow...
http://endless-sphere.com/forums/viewto ... =+shenzhen

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 07 2013 2:45pm

sk8norcal wrote:hey shenzhen-ex,
when you are done, you should let this guy try it,
a vblogger that i follow...
http://endless-sphere.com/forums/viewto ... =+shenzhen
Sk8...Unfortunately I can't watch the video (YouTube is bl0cked here). I will check it out the next time I am in Hong Kong.

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 08 2013 12:23pm

my rear axle snapped within 20 seconds.

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MAGICPIE3FOCUSPOWER   10 kW

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Re: My first eBike build: DH 2WD in China

Post by MAGICPIE3FOCUSPOWER » Aug 10 2013 8:10am

Well done!
Build looks very clean and pro! :mrgreen:
Nothing is perfect until I touch it...

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teklektik   10 GW

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Re: My first eBike build: DH 2WD in China

Post by teklektik » Aug 10 2013 8:40am

shenzhen_ex wrote:my rear axle snapped within 20 seconds.
Ouch! Really sorry to hear that... I'm unfamiliar with those motors, but at only 48v and half the load (2 motors), that seems really surprising....

Just out of curiosity, did you set the controller block time to 0.1sec to essentially disable the initial 'unrestricted current limit' operation? If not, then the programmed 30A limiting may not have been in play (yet) if you went WOT off the line. Just a thought....
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Re: My first eBike build: DH 2WD in China

Post by litespeed » Aug 10 2013 8:52am

Well that sucks!

Do you think too much torque or bad quality?

Tom
I'm married so you know I'm no stranger to pain!

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 10 2013 11:16am

teklektik wrote:
shenzhen_ex wrote:Just out of curiosity, did you set the controller block time to 0.1sec to essentially disable the initial 'unrestricted current limit' operation? If not, then the programmed 30A limiting may not have been in play (yet) if you went WOT off the line. Just a thought....
I did not set the controller block time limit. I do not think my controller is programmable.

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 10 2013 11:22am

litespeed wrote:Well that sucks!

Do you think too much torque or bad quality?

Tom
Tool much torque:NO
Bad quality: Maybe

Actually I think that I may not have had the adapter on the left (see image below), and the nut on the right tightened sufficiently.
Image

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Re: My first eBike build: DH 2WD in China

Post by jansevr » Aug 10 2013 11:40am

i think the main problem is the poor quality of the axle...which is really too bad because this looks like a well thought out build and a very clean looking setup!

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 10 2013 12:32pm

jansevr wrote:i think the main problem is the poor quality of the axle...which is really too bad because this looks like a well thought out build and a very clean looking setup!
You got me thinking...."if i replace the axle it will break again"....

Maybe I should build another adapter on the broken right side, similar to the one on the left in the image above.

Like this.......
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Re: My first eBike build: DH 2WD in China

Post by jansevr » Aug 10 2013 2:16pm

this might be possible...a combination of the adapter and possibly some dp420 (the epoxy doc recommends for his torque arms that he has sold quite a few of) might work. its hard to see in the picture, but would also depend on where the axle broke. did it break close to the middle of where the "adapter" would be? this would probably be ideal, but if the axle is so soft and prone to breaking to begin with - it is still questionable how long a fix like this will last.

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Re: My first eBike build: DH 2WD in China

Post by kfong » Aug 10 2013 3:12pm

Nice build. Sorry to hear about the axle issue.

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shenzhen_ex   100 W

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Re: My first eBike build: DH 2WD in China

Post by shenzhen_ex » Aug 10 2013 3:51pm

kfong wrote:Nice build. Sorry to hear about the axle issue.
kfong, thanks. And I will work out the axle issue!Thread I created to seek help with my axle issue

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Re: My first eBike build: DH 2WD in China

Post by cassschr1 » Aug 10 2013 9:45pm

I didn't look at the links in the posts but I feel you just had some bad luck there.

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