Specialized Big Hit FSR with midmount

[El Duderino]

Ah,

I am sooo last year!

Rui, it was the LEDs rather than the brake light (I'm a bit wary of setting up the brake lights, for fear of attracting too much attention from plod. You dont see bikes with brake lights round here). I didnt want to use the main battery. My thoughts being that I want lights even if I kill the battery on an over long journey (like you'd have with a car)... plus the headlight I'm in the middle of building is using a couple of high power LEDs that would cause an unnecessary drain on the main battery. I have a stock of a couple of hundred 18650's left over from a research project that is now steadily being eroded for stuff like this...

Keep it up Tench. I am in awe.

C

[Hyena]

Actually a similar thing is used on that stupidly expensive carbon fibre ebike, the blacktrail - which has been out for about 2 years so you're even more behind the times



I use a couple of bright red cree star boards stuck directly to the back of a small phone charger (dc/dc converter) which is on a bracket strapped to my seat post with what is normally the AC input running back to my main pack voltage. It kills 2 birds with one stone - mounting the DC-DC converter somewhere and how/where/what to stick the LEDs to.

But I've been playing with the surface mount versions of a similar thing to what you're using around your headlight Tench. You get them on ebay too and they come in a variety of spacings from 30 to 125 leds/metre and also in a waterproof version with a soft epoxy stuff over them. Now that it's dark when I'm commuting home I'm going to run them down the back of my frame and also put a strip around my helmet. I'm tempted to do my jacket too but it might look a bit tron (they're alot brighter than the EL ones I've seen done though)

[Whiplash]

OK so you use the phone charger just as is? I like the idea! Will it work for a 10W headlight? you just run power into where it would plug into the wall socket?

[Jimbo]

Just stumbled across this thread and I'm blown away.

I didn't have the skills or the balls to consider chopping my big hit, hats off to you for doing a proper job. Did you heat treat the frame after welding or just go as is?

Massive respect for a professional build, you are a very talented chap!

[crusoe]

Wicked work! What exactly is that rear led light strip called? Something along the lines of http://www.lightdepot.ca/product_info.php?cPath=26_85&products_id=299

[iamsofunny]

If anyone is wondering, the recommended heat treatment is baking for 1 hour at 400F.
I didn't heat treat the frame I made because it's strong enough without.
As long as the head tube is well gusseted and the material is thick enough it won't break.
The material properties for 6061T6 are 62,000 psi whereas postweld heat affected zone is about 15,000-40,000. Post retreatment it's about 50,000.
My bike has 1.5" downtube .125 so the 0.625 total wall thickness would need over 10,000 pounds of force to break. Fatigue over time is another issue, but over the time metal regains most of its strength anyway. That's why the heat treatment is called 'artifical aging'.

[M1k3]

So pleased to see this build resurface,is there any news upgrades/test reports.really would love to get a build like this but just waiting to hear some more about mid mount hub motors

[Tench]

So pleased to see this build resurface,is there any news upgrades/test reports.really would love to get a build like this but just waiting to hear some more about mid mount hub motors

Hi M1k3, other than fitting a voltage monitor to my lights batteries it is still the same, this little device has a tri-colour led which indicates the SOC of the battery to prvent me from draining them too far, thats it, it is all finished. There was a motor mounting alteration which is on the previous page, oh and i need to get the programing cable so i can update the software to the latest version in the V3 CA it now has.
I have had a few days out on it now, mostly gentle stuff out with the wife on hers, i work from home so dont commute. I had one day out on my own slowly increasing the severity of the terain and steepness of banks etc, it took everything in its stride i need to get a rack on the car so i can take it upto the peak district to ride some of the severe rocky trails i used to do on the enduro bikes. On saturday i did about 20 miles going at the wifes pace (17-18 mph) and averaged 18 watts per mile, with over 1000w to play with in the battery that would equate to 55-60 miles.

I am designing another bike now, i think i enjoy building them more than riding them!

Simon.

[M1k3]

Thanks Tench glad this build is holding up,you really have a tall order to top this one,but I can't wait to see what you come up with.

[BATFINK]

Please show us how you made that cool angel eye light?

[Tench]

Hi Batfink, i was sure i replied to you earlier but the post does not seem to be here so i will do it again,

Here are some pics, they show the back of the ring and one of the two grub screws securing it onto the outside of the ebay light, you can also see the wires coming out the back, the other pic shows the led string that fits in the rebate i machined into it for them at the front. I hope this shows how simple it was to do, i would'nt be without a lathe at home now, how i managed before i dont know!

[BATFINK]

Thanks that's great. Cheers

Sent using Endless-Sphere Mobile app

[courcheval]

Simon, i dont know how to express my admiration for your skills...i m a fan

[pdf]

Still one of the best build's I've ever seen...

[Xanda2260]

Not sure how I missed this beast!
Simon, fabulous work. You've done the UK proud. Best build I have ever seen, and has convinced me that my trike needs some mid-drive awesomeness.
If you ever sell this thing, let me know

[jateureka]

Amazing build!

[MitchJi]

Hi Simon,

Awesome bike

D, building a frame is not as straight forward as it might seem, every aspect of the bike has an influence on the frame, to do a good job the bike has to be designed as a whole, the choice of motor, controller, batteries, cable routing, cable securing, wiring routing, sufficient space for the the wiring all these things have to be taken into consideration and integrated into the design, basically the whole bike has to be designed down to the last detail before any of it can be built, that is if you want to build things the way i like to. i have about 3mm clearance between my pedal cranks and the motor mounts on either side so even the motor spindle could not be designed until i had chosen my pedal cranks and BB, those details dictated the motor offset which dictated the design of the front sprocket carrier and the chain run. Finding the right cranks to cut the spiders out of to allow me to fit it all between the pedal cranks whilst keeping it looking central and getting the chain where i wanted it. on this build everything just fits. To build a frame would involve designing a whole bike and making many more components than just a frame. I started this one by cutting some cardboard templates of the motor, batteries and controller, then i taped them to the bike frame, i spent a couple of evenings moving them around thinking of all the possible implications associated with that layout until i found the layout that i have now, then i stuck them in place and sat with a note pad and a couple of rulers, i try to think of every single small detail and how i will do it, when every single problem has been solved and i know exactly how i am going to do it down to the last tiny detail i will set about it with the hack saw and get stuck in.

Now what was the question,,oh yes,,how much for a frame ,,, priceless!!

Might make sense to either sell copies of your existing frame or your next build (build more than one).

[courcheval]

I think Simon's plan is to build frames capable to recieve any kind of engine and batteries to help building finely integrated mi drive electric bikes...

I just acquired Simon s prototype and i can't believe my luck...it s incredibly well thought, easy and simple to use, no loose wire anywhere...and a pure joy to ride. In Calais, the guy responsible for the mountain bikes department at Decathlon who let us plug the charger had stars in his eyes...he got a ride and you could feel how enthousiastic he got...

Thanks Simon for leaving me your bike, as i told you, i almost feel i dont deserve it since i m a total newbye regarding electric bikes...

[tedcs]

Wow
My braincell exploded

[Tench]

Might make sense to either sell copies of your existing frame or your next build (build more than one).

You hit the Nail on the head. I am designing a new frame with the intention of making it suitable for a multitude of different motors from hubbies in the wheel to a variety of mid mount options. I am going to build several complete bikes all with different motors to work out the finer design issues and then when i am happy i will produce a batch of frames.
It will of course have to look like which ever motor is used that it was made just for that motor, i wont be happy with the design untill i achieve this. It also has to be able to accomodate a multitude of battery options and controler sizes.
I allready have the basic design planned out, i just need to buy several motors now to work out the finer details.

[wildharemtbkr]

Ebiking just got a way brighter future! Can't wait! Nice build, obviously I really like it. Lucky score for the guy that got your bike!

[El Duderino]

Might make sense to either sell copies of your existing frame or your next build (build more than one).

You hit the Nail on the head. I am designing a new frame with the intention of making it suitable for a multitude of different motors from hubbies in the wheel to a variety of mid mount options. I am going to build several complete bikes all with different motors to work out the finer design issues and then when i am happy i will produce a batch of frames.
It will of course have to look like which ever motor is used that it was made just for that motor, i wont be happy with the design untill i achieve this. It also has to be able to accomodate a multitude of battery options and controler sizes.
I allready have the basic design planned out, i just need to buy several motors now to work out the finer details.

Time to start saving then. Kids didnt need to go to College anyways...

[Phoebus]

Good god this is insane.

Incredible craftsmanship.

[courcheval]

In the mountains, the range uphill is about 20 kilometers (40 km forth and back).
You need to leave the controler cool down from times to times if the ascent is continuous...the engine will stop itself anyways to avoid burning.

Reactions from people crossed on the mountain path go from sympathy to admiration when they witness you getting to refuges silently on the top...when they hear the noise of the engine, some cant help yieling a "cheater!"

Test yesterday on both tarmac and gravel gave 41 kilometers up and down with a total of 1200 m climb (1h40 total) at an average of 25 km/h.
Test today mainly on gravel : 11km uphill sucked half of the 15 Ah available, again at 25 km/h average with 700 m climb.

[courcheval]