I've now 'properly' mounted the battery.
This build is still 'slowly' in progress, but it's now functional to the point I can use it to commute. For me that's a significant milestone, as including the time taken to re-thread all my rear wheel spokes, so far this build has taken me over 5 months of mostly continual work when I found time, in order to get it to this stage.
Anyway, I'll let the pictures tell the rest of the story.
The battery is well padded where it rests on the frame, and back of the seat. The elastic straps take a lot of the weight, so the weight is evenly spread, not focused only on the main frame section in the middle. There is super soft padding inside the bag as well firmer rebound padding on the frame itself. The zip ties are there to prevent the battery falling off in an accident or very large bump. The bag is there partially to disguise the battery, and partially to protect it from any water splashes/rain. Although if I do ride in the rain, I think I will have to cover the whole rear with a garbage bag or 2.
There are only 3 concerns/issues I have with the bike at this stage.
The first is minor. The top edge of the battery sticks into my back a little through the seat mesh. I've maneuvered the battery down and back as far as I can without having to redo all my mounting, but I can still slightly feel it. It isn't a major concern when riding normally, but I can feel it when I hit larger bumps. I'll see how it goes, and if it's a big issue I'll have to reposition it further back.
The second problem may or may not be an issue. When I engage Regen, I can hear a slight creak. coming from the axle/motor area. I've tightened the axle bolts and torque bars as much as I dare, but can still hear the minor creak each time I engage regen after accelerating. It only occurs if I accelerate first, so it is definitely something to do with the shifting axle rotation force. I'm going to continue using regen and see how it goes. Best case it's just the rear stays or frame, worst case the axle somehow is moving, but even then, it's got 2 torque blocks, 4 torque washers, and 2 tight axle nuts...I'm pretty sure it's not going to spin in the dropouts.
The third issue is also minor. I can't use first gear as the derailleur hits the motor side cover bolts. Solution - buy lower profile bolts.
Not sure if I'll get it out for a longer ride today or tomorrow...I'm pretty sick with a cold atm, so pushing it to even cruise around the block if I'm honest.
Major things still to go on this build are:
-CA V2 (recycled from my Stealth Fighter when I get an Adaptto Mini-E for it)
-ATS Speed drive 1:1.65 - eta Jan-Feb 2015
-New battery pack - Built from 18650s to slide inside the frame. Currently planning for a 15 or 16s 6P pack with 4p sitting inside the frame before the rear stay mounts and 2p sitting behind the mounts before the controller. Measurement wise, it all adds up with room to spare.
-Re-mount the controller so it is heat-sinked to the frame.
Minor things still to do:
-Additional power button inside handle bar end for added security. Currently just the switch on the handle bar turns the bike on.
-New chain
-Re-mount the rear tire...I mounted it backwards.
No big deal though.
-Light/s - Will probably just mount 1 or 2 of the standard ebay 'ebike' lights as they are so cheap and do a decent job.
-Light switch - Will use the other handlebar end to mount a switch for the light/s.
-If necessary, external cable routing in order to fit new battery pack.
-If necessary, better front brakes. Maybe some Magura hydro rim brakes...MT11 I think. The current brakes work...but not so well now with the added weight.
Any feedback welcome.
Cheers
