ZOMGVTEK's 2011 Build Thread...

[ZOMGVTEK]

I got my cheap 10mm wrenches in yesterday, got around to making a torque arm.
Only finished one, the other one will be done tomorrow, and current is going up.
They were about $3 each wrench, shipped. Quite the cheap and sturdy solution.




It turned out fairly well. Looks to be extremely sturdy, and fits very tight.




My fairly well calibrated speedo says over 40MPH... I will do a run with a GPS tomorrow.

The bike has been great thus far. 40 MPH is quite fast, considering its over the speed limit of most places I tend to ride my bike.

[ZOMGVTEK]

40.5 isnt bad...

[sn0wchyld]

PowerPole'd the chargers and PSU. Some of the stuff finally shipped from China, still waiting for the backordered 4mm HXT's so I dont have to cut off all the connectors on the LiPo.

Hey zomg what are you useing to gob up you terminals there?

And how long did it take hk to restock the hxts? Cause im waiting on the same stuff now....
Chrs. Nice bike btw.

[ZOMGVTEK]

Hey zomg what are you useing to gob up you terminals there?

And how long did it take hk to restock the hxts? Cause im waiting on the same stuff now....
Chrs. Nice bike btw.

Thats just some hot melt glue.

HXT's took about 3 weeks to ship. They weren't officially 'in stock' until about 4 weeks after I ordered... Then they quickly disappeared.
Im now on week 2 of waiting for balance extensions... My friends bikes both need a pack more to run 88V. But thats not a big deal, since they still did essentially nothing yet to get the bikes up and running.

[ZOMGVTEK]

The other wrench went on the other side, and the current went up to 60A. A bit more acceleration in the low to mid range, but not as much as I was expecting.

Position 1 on the switch is now 35% throttle, 99%, and 120%... I hit 46 on GPS at 120% throttle, and probably could have creeped into 47 with a little more room. It picks up speed really slow past 40 or so, and you're covering ground fairly fast.

I probably should have some sort of protective gear past jeans..

[ZOMGVTEK]

I did a bit of a refresh on the setup... The controller is now mounted under the batts on the top rail, more hidden. Front and rear derailers are gone, as well as the shifters. I put the cheapo switched brake levers on, and will get a hydraulic disc setup for the front soon. Until then, burnouts are hard since the motor is cut with the brake application. Nice for safety, and its easier to kill the cruise by just hitting the brake... I put 10 gauge phase wires out of the controller, and cut the motors wires down to a few inches. Controllers power inlet is now the same 10 gauge as well, traces to the FETS are beefed up.

I still need to hold the batteries into the L bracket a bit better than a single strip of tape, mount the BM-6's better, and figgure out a easy way to run the Watts Up meter so it can at least read 44V of the 88V, and tell me the current and 1/2 power ratings.

This is the only pic I have for now, a dark phone image showing my charging setup.


Ethernet cables made into a parallel 6S charging harness. Each charger handles each side as a 20AH 6S LiPo pack, charging at 10A/200W.

One of my friends started putting some time into his build. Heres the only picture I have of his bike, but he has the same stuff I do, so you can assume what its going to end up like.
Should be up and running by the end of the week.

[sn0wchyld]

hey mate
lookinng at your setup again you may want to check the range of your rear suspention, looks like if you compressed it more than about 50% you might get close to rubbing your main lead wires from the batteries on your tire...

on a different note, how do you find riding with the wider bike? im thinking of mounting batts in a similar place....

cheers

[ZOMGVTEK]

hey mate
lookinng at your setup again you may want to check the range of your rear suspention, looks like if you compressed it more than about 50% you might get close to rubbing your main lead wires from the batteries on your tire...

on a different note, how do you find riding with the wider bike? im thinking of mounting batts in a similar place....

cheers

I since put a little guard in place, which should eliminate the wire from ever rubbing. It generally wasn't that close before, the rear suspension is super stiff.

Its a bit wider than I assumed it would be, but its really not a issue at all. Its marginally in the way if you were to pedal, but it probably wouldn't be hard to adjust. I just don't pedal, so its just fine for me.

[ZOMGVTEK]

Heres a shaky video... The mic didnt manage to pick up super loud wind noise that I assumed it would. It was probably mostly the position of the mic and the angle I held the camera at. I need to get a good solid mount and make something a bit more exciting.

http://www.youtube.com/watch?v=MTU4ovuF75c

[ZOMGVTEK]

Finally hooked up the Watts Up to one 22V string, first time actually measuring the power the bike is using.
Now, this is only one of the 4 22.2V packs, so voltage is 4x higher at the controller

24.46V
71.40Ap
23.29Vm
1665.0Wp

6660 Watts Peak, Total, = 8.93 HP.

This was done at 99% throttle, motor stalled into a wall. 6660 Watts isnt bad for a stock 1000W Golden Motor knockoff.
No torque plates, just one 10mm wrench bent into shape, super tight axle nuts, and nordlock washers.

If the torque increases linearly at 100A, I think wheelies would be a major concern. It already wants to lift if you're slouched back.

[icecube57]

Isnt much life left in that GM motor be careful at these power levels. As said earlier your windings are a healthy brown color.

[ZOMGVTEK]

One of the halls would quit on my motor when it warmed up. I made a thread elsewhere regarding this, but might as well throw it in here to document it along with the build.







New halls... This was then covered with silicone.





The new halls went in today, and the motor is running alright. At high loads, and very low speeds, the motor is quite rough.

[ZOMGVTEK]

Isnt much life left in that GM motor be careful at these power levels. As said earlier your windings are a healthy brown color.

I'm actively looking for a spare GM, or a replacement motor that can take more power. Id like to be able to throw 10KW at it. The acceleration is OK with a fresh pack at 70+A, but when the pack drops down to 90V or lower, it starts getting a little sluggish.

I guess I can always just run more voltage...

[ZOMGVTEK]

Heres some more recent photos of the bike...

[icecube57]

From my understanding the GM is basically a 9C 9x5. Slightly faster wind. At 48v it should do 33mph. But at these power levels you shouldnt use a motor that continues to draw insane power at high speed. Yes it technically give it more torque at higher speed but low KV motors are more suited high power instead of a high KV motor like the GM. I suggest that you drop down to a 5x12 or a 6x10 or a 7x9

[ZOMGVTEK]

My motor always did 24-26 MPH at 48V. It never went faster than 26 MPH, on 12S LiPo or 48V of Lead. The older GM hubs were higher speed than these.

[ZOMGVTEK]

Is it a bad idea to entirely submerge the motor? We used to do it all the time.

The blue NEXT bike my fried had was taken out of commission after the front rim cracked. It was easier to just get a new $150 bike, which rides WAY better anyways.
It was less than 2 hours to get the new bike up and running.



Here is all 3 bikes together. Identical setups, on assorted cheap bikes.



Heres a fairly low quality video thrown together with assorted clips, intended for another purpose.

http://www.youtube.com/watch?v=ijzDT1Bz6u0

[ZOMGVTEK]

I had the controller flashed to 60A after the hall failed, and the CA was reading about 95A peak. I dropped it down to 40A, and its now reading 65A peak, average of 4400W during acceleration, and its really not notably slower. I raced my brothers bike that I normally SLIGHTLY pull on, and he had slightly more mid range punch, same at the low and high end. I was abusing it fairly good and the motor stayed cool to the touch, only slightly smelled. I don't think the motor is putting out any more power past 60A or so... I will try messing with it more, bump it down to something like 20 just to see, then up to 80 in increments of 5.

I inflated the tires to about 60PSI and I save about 300-400W at 40 MPH, its down to below 2KW.

[ZOMGVTEK]

Mounted up the chargers onto a board, hanging in the garage. Also made one torque plate, the other one will be done sometime in the future.

[ZOMGVTEK]

My bulk charger is done. 4x Meanwell SP-500-24 in series, 4.1V/cell target, rated at 20A, set to about 15A.

[ZOMGVTEK]

After much hassle, I managed to get a thermistor in the windings of the motor. Its jammed under a bunch of windings, and held in by a dab of silicone. I put it in the area I suspect to be the hottest portion. The display itself isn't yet mounted, but I warmed the motor up to the point where it starts to feel 'soft' on regen and hooked it up. I normally take the motor a bit past this daily, and the thing claims it was 142ºC... I suppose thats why my windings are dark.

This motor heats rapidly at 6-8kW. I need to find a good way to get some serious airflow over the windings, the bike is too slow on 6kW, 8 gives it a bit more pep.

[auraslip]

Man you go all out! Very nice setups!