48v 1000w Conhis 2004 DH Cannondale Jekyll (Lots of pics!)

Hey whats up people? I started a thread on the no-hub forum but was soon convinced by one resident to go with a hub motor and that's just what happened.

The bike I picked is a 2004 Large frame Cannondale Jekyll 500. I got it for $500 and just needed to tighten a few bolts and return the calipers which whoever installed the new pads failed to do.



The bike has a 135mm drop out perfect for a 6 speed hub motor.



After placing my order for motor and cells I started on testing the lighting loom I wanted to make for the bike.
The 12v system on the bike comes from a golf cart voltage drop, I wanted to include:
1) Twin front spots
2) Rear light
3) Brake light
4) Rear turn signals
5) Horn
6) 12v cigarette socket



Each spot has a master switch so you can choose between them or have both on at once.


























Lighting loom coming together while waiting for motor to arrive.



Reed switches have been mounted inside two old pen ends, drilled through and sprung for triggering the brake lights.



Two torque arms sold separately by Conhis.



Closed side of the cardboard mock up battery box.



Closed side of the cardboard mock up battery box with clamp attachments.



Open side of the cardboard mock up battery box.



1000w Conhis hub motor on a 26" rear wheel with a new cheap-ass tire.



Box taking shape from the 3mm birch plywood, I glued the box together and used duct tape to hold it together before fiberglass.



12v cigarette socket, I plan to use this to charge/run my phone/GPS from while riding.



Two stage key ignition, first stage is the 12v second is both.



Added some fake car air intakes to help the electrics breath inside the battery box.

Part two of my bike build and lots more pics.

Top fittings to attach the battery box to the frame.















Controller fitted to lower bottle mount on frame.





New riser bars and stem fitted for more room to fix things and better riding position.







Box before fiberglass held together with only duct tape.



Inside lid after mat was applied.



Inside box after mat was applied.





Box together after fiberglass mat first clean up.



Trying for a fit after fiberglass mat on the inside. Next clear up the outside and paint.

I like your taillights and turn signals, it reminds me (in a much more refined way) of something:
http://www.endless-sphere.com/forums/viewtopic.php?p=268589#p268589
Hopefully the trashed pics will eventually be restored from backup, but it's still clear enough.

Where did you get your lights and LED bulbs replacements?

How well do your headlights work? Any night road pics? (preferably with another known light source also in the pic shining next to where these do, for comparison)

Do you like your LS-CA?

Interesting idea about the pen cap brake switches. You just press them in manually as you engage the brakes?

Impressive build, love the torque arms for the rear.....where did you order them from?

Love the "fake" car air intakes

Look great. A couple ideas for you. Source some ebike brake handles that have the microswitch built in for brakelights. Also cut the torque arms just past the point where the bolt goes through the slot and have someone weld a solid piece of steel on the end so the bolts can't "slide" in that slot. I actually cut both pieces of mine and then welded them back together.

I like your taillights and turn signals, it reminds me (in a much more refined way) of something:
viewtopic.php?p=268589#p268589

Thanks the metal need to be done a bit better and painted but ty.

Where did you get your lights and LED bulbs replacements?

Ebay! Rear light/brake light is for a atv. The led bulbs were $16.96 from China no link sorry.

How well do your headlights work? Any night road pics? (preferably with another known light source also in the pic shining next to where these do, for comparison)

Don't have any pics yet other than ones from tests above, my first BMS was faulty so waiting on a new one to run all my tests. I will make sure to add some for you asap next to a standard cheap bike light.

Do you like your LS-CA?

Again no real opinion yet will update.

Interesting idea about the pen cap brake switches. You just press them in manually as you engage the brakes?

They are pressed in so the handle can move free, the contact is made when a magnet (not pictured) touches the end of the reed switch.

Impressive build, love the torque arms for the rear.....where did you order them from?

They are from Conhis Motors site under accessories.
http://www.conhismotor.com/ProductShow.asp?id=166

Love the "fake" car air intakes

Thanks since moving to the USA I see them on all brands of cars so I figured they must be cheap. Was thinking of kitting the battery box out with 12v fans but I think this is a simpler method.

Look great. A couple ideas for you. Source some ebike brake handles that have the microswitch built in for brakelights.

Do they make Hydrolic ones because I can't find any and am not giving up my brakes for cable.

Also cut the torque arms just past the point where the bolt goes through the slot and have someone weld a solid piece of steel on the end so the bolts can't "slide" in that slot.

Thanks that's a good idea I think I will do that.

Olivettibakebean said:

Look great. A couple ideas for you. Source some ebike brake handles that have the microswitch built in for brakelights.

Do they make Hydrolic ones because I can't find any and am not giving up my brakes for cable.

Also cut the torque arms just past the point where the bolt goes through the slot and have someone weld a solid piece of steel on the end so the bolts can't "slide" in that slot.

Thanks that's a good idea I think I will do that.

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Just get yourself a pressure switch from a small car, it SHOULD work, but I am not sure of the pressures in a bike brake system, I would try one for an old VW beetle, that is probably the lowest pressure one you will find because it is still a manual design not power assisted...

You can also buy replacement banjo bolts with built in pressure switches. For use on race master cyl. and motard conversions for dirt bikes. Not sure what size thread your bike uses but if its 10mm its an easy thing to find at bike bandit or dennis kirk.

Just get yourself a pressure switch from a small car, it SHOULD work, but I am not sure of the pressures in a bike brake system, I would try one for an old VW beetle, that is probably the lowest pressure one you will find because it is still a manual design not power assisted...

This is a great idea, I have a history working on custom VW's and I think it could defiantly work, I just not too sure right now about the strength in the joint. Also don't have the money right now to have to replace the lines if it goes wrong. Def an idea for the future and would make a cleaner more stealth build. The real worry is the strength as my riding style is pretty aggressive.

You can check out the last VW build on my site if anyone is interested http://www.topsoilproject.com under projects.

Cool here's mine! Im in the middle of doing a front end with 24" of travel to match the rear 5x5's and coilovers.. Water pumper too with 200HP for now and a 091 bus box...

Whiplash said:

Cool here's mine! Im in the middle of doing a front end with 24" of travel to match the rear 5x5's and coilovers.. Water pumper too with 200HP for now and a 091 bus box...

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OMG I love it! Dream dune buggy!

Thanks! I have a LOT of work in it! kicks butt in Glamis! and is still "technically" street legal! You will love the Conhis Motor, I have one with about 1000 miles on it and its still going strong and on 14s pack it does like 36MPH!

This was mine when I left it in the UK. Really like to do a ev 356 speedster one day out of a kit of course.

Whiplash said:

Thanks! I have a LOT of work in it! kicks butt in Glamis! and is still "technically" street legal! You will love the Conhis Motor, I have one with about 1000 miles on it and its still going strong and on 14s pack it does like 36MPH!

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I have always dreamed of driving one around dunes laughing like Steve McQueen in The Thomas Crown Affair. If only I was closer I would jump at a chance to ride riding shotgun.

Yeah really looking forward to getting the bike running and doing some miles on it. I have lost loads of weight since slowly getting over a back injury so hoping to go a bit faster than I would have a few months back.

I really like the "large emblem" busses! Ultra cool! If it was not so hot out here, I think one would be fun for a daily driver. Old school SUV!! :lol:

Whiplash said:

I really like the "large emblem" busses! Ultra cool! If it was not so hot out here, I think one would be fun for a daily driver. Old school SUV!! :lol:

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Yeah I always wanted a split bus since I was really young, because of the wrx Scooby engine we were able to fit air-com and water matrix heating so it can be both a hot and cool ride. Think the kids in the back would have a blast on school runs when the front wheels lift off the ground and she peals past Porsche's on two wheels.

Niice!

Whiplash said:

Thanks! I have a LOT of work in it! kicks butt in Glamis! and is still "technically" street legal! You will love the Conhis Motor, I have one with about 1000 miles on it and its still going strong and on 14s pack it does like 36MPH!

Click to expand...

If its not too personal how much do you weigh? and whats the bike your kit is on? I have 16s headway 48v 12ah.

First dry day in a while, took the chance to get out and do some sanding.







This is the second sand, not going for crazy perfection but there where a few pits to fill.





My battery built but still waiting on bms.

Another dry day and another day sanding fiberglass. This must be why there are very few fiberglass battery boxes, sanding it is horrible.

Been dodging the rain today and have the box ready for paint. Its not perfect but I'm sure I will scratch the hell out of it in a week anyway.