knoxie wrote:you need a bomber mate, that's it I'm ordering you one! on the house
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yeah, it's been a very destructive streak, that's for sure.
i've always intended to lace the M/C tire onto the hs3540, so let's just consider the old 9C just the test platform.
it will go nicely on another bike, once i replace the side cover:
the sheer failure is well known, right? but i'd expected the threads would get sheered, not that the entire thing would crack off.
dbaker prolly had loctited the threaded adapter on. good stuff.
so moving along... i put in a good four hours last night rebuilding the DH Comp, starting with the upgraded hs3540.
the lyen ebike tester show that the blue hall wasn't working (solid red light)
but with a multimeter, i discovered a short between Blue and GND! Dang it! This then echoed in my mind...
John in CR wrote:Be sure to change out the hall wires too.
I could have ignored halls and installed sensorless controller, but would have preferred to use the sensored controller. so carefully removing the sidecover... can you see the frayed cloth? that was visible from outside and i suspected there was damage to the wires...
but with a magnifying glass i couldn't see any exposed wires:
hmm. i checked the halls with the ebike tester again, and they all work - see the red lights going on and off when the magnet passes?
so the short must be in the wires, and if not now, maybe just when compressed in channel, so let's give the wires some more room:
i then taped up the wires where the cloth was torn, tossed the wheel back together, tested it on the bench and it sang beautifully! i ran it no load, WOT for several minutes, and watched as the motor temp went from 16C to 20C. woohoo!
i tossed it on the bike, and then lined the brake up perfectly with some washers - it rubbed with last motor and i couldn't stand any more NOISE. we learn. we learn...
i used a wire tie to clamp the wires away from the disk screws, just to make sure there wasn't any rub, and fired it up:
no longer singing, that's for sure. and when i put my ass on it and tested in the alley, you'll notice there's no mechanical rub under pedal power but with some throttle..:
yeah, we're used to this now...
no worries. just time to fire up the brand new sensorless controller. oops, gotta replace the connectors with bullets, and might as well watch some hulu:
i tossed it on, and it tested fine, though a bit anemic... well, we'll see in the morning... i think it'll make it to work at least. i actually had trouble falling asleep cause i was excited to ride it.
and it did:
i had the old lipo in the pocket again, connected by alligator clips to power temp sensor, and damn, i never got above 64C! the controller was probably programmed with conservative settings so no idiots would burn up their motors:
Overall impressions of this build so far:
- brief jerky start from standstill
- surprising low torque during initial acceleration
- lackadaisical throttle response after coasting
- curious grumbing in middle range, wasn't sure if it was something in the motor, but it disappeared at higher speed
- eventually got up to max 38mph downhill, which was fresh after slowpoking around
- brakes feel good, and thankfully are now quiet due to proper alignment (lesson learned: tighten axle before aligning
- need to reprogram to get regen?
so let's see if i can make it through the day without destroying anything - i might even like to get thru the week, but let's not temp fate.
ebikes are reliable, just as long as you're willing to work on them all through the night, if that's what it takes.