Full-throttle's 2nd - in progress

[full-throttle]

The "no music" version is uploading now
http://www.youtube.com/watch?v=-_adbELvBZY
should play on mobile devices

[Animalector]

Nice work on the latest video. love the rear-shots of the gear changes under load.
Andy

[Hyena]

Yeah the rear shots with gear changes are cool. Nice vid.
Hopefully I can make it down soon to check it out

[Whiplash]

Yes, very cool and actually better with no music! You get to hear the bike! Also I have to say that is a BEAUTIFUL place to live!!

[Cyclebutt]

Really like the power packs. How much time (distance does not apply ;o)) per ride/charge can you get out of that set-up. Any and all details about your power source would be greatly appreciated. Great video! Nice soundtrack and editing, good job!

Waiting on my 20 aHr, LiFePO4 (heavy) pack now. Will use a backpack for initial testing but really like those lightweight jobs your using. Next time..... cheers!

[kentlim26]

Wow!! wonderful, full throttle , nice work on your video. I do like sweet birds sings crips !! i saw the whole video, very well created. thanks for the input. i like it very MUCH.

ken

[deecanio]

Hi FT,

Thanks for taking the time to repost with no audio, drive sound is not too bad at all, im impressed!!
For the money being asked i don't think the gng kits are at all bad, hopefully you guys that already have one will find the sweet spot before things go wrong so we know whatit can take comfortably, FT's looks adequate for me tbh but always nice to have a little more very tempted to get one myself and have a liitle play, thx again FT.

D

[full-throttle]

Really like the power packs. How much time (distance does not apply ;o)) per ride/charge can you get out of that set-up. Any and all details about your power source would be greatly appreciated.

The individual cells can be found here:
http://www.hobbyking.com/hobbyking/store/__18562__Turnigy_5000mAh_1S_40C_Lipoly_Single_Cell_.html
http://www.hobbyking.com/hobbyking/store/__18560__Turnigy_5000mAh_1S_20C_Lipoly_Single_Cell_.html
http://www.hobbyking.com/hobbyking/store/__18594__Turnigy_5800mAh_1S_25C_Lipoly_Single_Cell_.html
and a complete pack assembly is offered by jonescg viewtopic.php?f=31&t=38252
Of course you can simply get any LiPo packs and connect them in series/parallel.

My pack is 14s2p so a common 16s LiFePO4 (58.4Vmax) charger can be used. It's in 2 halves, aka 'riding saddle' arrangement. Each halve is 140 x 120 x 50mm and weights 1.7kg, for a total of 3.4kg. Not sure of run time yet, should be able stretch to 50km/2hr ride. I can always make the pack bigger (14s3p or 14s4p) or just carry another one in the backpack.

[Cyclebutt]

Really like the power packs. How much time (distance does not apply ;o)) per ride/charge can you get out of that set-up. Any and all details about your power source would be greatly appreciated.

The individual cells can be found here:
http://www.hobbyking.com/hobbyking/store/__18562__Turnigy_5000mAh_1S_40C_Lipoly_Single_Cell_.html
http://www.hobbyking.com/hobbyking/store/__18560__Turnigy_5000mAh_1S_20C_Lipoly_Single_Cell_.html
http://www.hobbyking.com/hobbyking/store/__18594__Turnigy_5800mAh_1S_25C_Lipoly_Single_Cell_.html
and a complete pack assembly is offered by jonescg viewtopic.php?f=31&t=38252
Of course you can simply get any LiPo packs and connect them in series/parallel.

My pack is 14s2p so a common 16s LiFePO4 (58.4Vmax) charger can be used. It's in 2 halves, aka 'riding saddle' arrangement. Each halve is 140 x 120 x 50mm and weights 1.7kg, for a total of 3.4kg. Not sure of run time yet, should be able stretch to 50km/2hr ride. I can always make the pack bigger (14s3p or 14s4p) or just carry another one in the backpack.

Wow! Now I wish I could cancel my LiFePO4 order! I noticed Hobby King had some warnings about soldering those tabs. Still, my next pack will DEFINITELY be home build out of these things! Thanks, Full-throttle.

[Whiplash]

Yes! I didn't know you could get these! I'll definitely be doing this as well! Seems like its about the same cost too!

[t3sla]

best to weld over solder with something like this
http://www.candlepowerforums.com/vb/sho ... er-for-100

[full-throttle]

best to weld over solder with something like this
http://www.candlepowerforums.com/vb/sho ... er-for-100

MarkAW built a welder and wasn't very impressed with the results

Also I have to say that is a BEAUTIFUL place to live!!

Thanks, our suburb is 6th (down from 4th last year) most liveable in Melbourne which is the most liveable city
http://theage.domain.com.au/greater-melbourne/the-list-melbourne-suburbs-liveability-ranking-revealed-20111122-1nrv2.html
To get to the 30km worth of trails I literally have to cross the street

[remf]

Fantastic work FT. That's the best value, most powerful mid-drive bike I've ever seen. The packs are awesome too. Are there any plans for higher voltages?

Take it from a Sydneysider, Melbourne is not only the most liveable big city on earth, it's also the best for off-road riding.

[t3sla]

clifton hill is dope, that bakery near the paint shop is niiice

[rodgah]

hey fullthrottle,

I thought you replaced the stock belt with a htd, but it looked like you went back to the stock belt? does the spring for the belt tensioner rub on the face of the bearings?



Rodger

[full-throttle]

Due to popular demand I ended up using the original belt and idler. The shorter belt is likely to shred its teeth off.

The spring on the idler doesn't rub on the bearings. You can see it @0:35 in this video:

[rodgah]

oh ok yes its only a 15mm wide belt?

is there enough room between the cranks to fit a 25mm belt in there? and what is the tooth count on the 2 pulleys, I have searched but I may have skipped over where it was mentioned?

Rodger

[full-throttle]

Yep, the belt is 15mm. Pulleys are 14/80 viewtopic.php?f=28&t=42785

There's def enough space for 25mm belt. The clearance is 15mm at the smallest. Not sure how the small pulley is attached to the motor though. It may be hard to replace plus the shaft will be too short..

[GCinDC]

My pack is 14s2p so a common 16s LiFePO4 (58.4Vmax) charger can be used. It's in 2 halves, aka 'riding saddle' arrangement.

FTslipopack.jpg (36.46 KiB) Viewed 388 times

looks like you add a bit of copper on the tabs?

did you solder in balance leads at all? or have a way to monitor individual cell voltage?

i noticed you did a similar thing on your stealth. sure cuts down on extra wires and unecc bulk, huh?

[full-throttle]

looks like you add a bit of copper on the tabs?

Copper bus bars added to lower resistance and help with integrity of the pack.

did you solder in balance leads at all? or have a way to monitor individual cell voltage?

There are balance leads that were added later.

i noticed you did a similar thing on your stealth. sure cuts down on extra wires and unecc bulk, huh?

Cuts down on bulk a fair bit - over 10mm in height. The pack is much neater as well. Weight not so much - the entire pack is 3.4kg vs 4kg if using unmodified multiple packs.

[shorza]

I think Greg is asking if you can measure each of the 2 cells that have been paralleled, which i don't think you could.
But if you did notice that you had a weak cell in a paralleled group of 2, you could remove them both and test them to see which is the weak one.

I think i'm confusing myself now

[sn0wchyld]

I think Greg is asking if you can measure each of the 2 cells that have been paralleled, which i don't think you could.
But if you did notice that you had a weak cell in a paralleled group of 2, you could remove them both and test them to see which is the weak one.

I think i'm confusing myself now

nope, you've got it.

[t3sla]

looks like you add a bit of copper on the tabs?

Copper bus bars added to lower resistance and help with integrity of the pack.

Where did you get the bars from?

[full-throttle]

Some copper rod, tinned with solder

Here are a couple of photos of the pack, note polycarb corners. 750ml bottle for scale. White plastic was hot-formed.

pack1.jpg (205.32 KiB) Viewed 508 times

pack2.jpg (131.82 KiB) Viewed 508 times

[sn0wchyld]

Some copper rod, tinned with solder

Here are a couple of photos of the pack, note polycarb corners. 750ml bottle for scale. White plastic was hot-formed.

pack1.jpg

pack2.jpg

damn man thats seriously small. Do you do any particular cell testing before putting them together like that? Any particular tips/things to watch out for for someone thinking of trying it themselves?