StudEbiker's S-750 build- Almost done.

[StudEbiker]

Well, I've been slowly making progress on this one for awhile. The motor is an E-bikekit.com rear 9c that was sent to me awhile back by Jason for review. The wheel came to me in really bad shape and he said I could keep the kit and forget about the review since the wheel was going to need so much work to get it true. I ended up taking it out of the original wheel and putting it in a Sun Singletrack wheel so I could have matching wheels. I am still working on getting the wheel trued up, but so far so good.

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[StudEbiker]

My cat sure seems to like the new bike. He's been curled up under it almost constantly since I brought it into the house from the garage last night. I think he likes the fact that the colors match his. it's unusual for me to have a bike in the house, and yes....the wife is out of town.

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[rkosiorek]

nah, your cat is just like mine. he wants to supervise and make sure he gets in the way as much as possible. strategically the best vantage point to acoomplish this from is right where he is.

you can confuse him though. just put an important looking open cardboard box just to one side of the bike. he will immediatetly occupy a new strategic location inside of the box.

rick

[StudEbiker]

Well, it rolls. Kind of nice to get to this point. I've been slowly putting this project together. It's nice to finally have rubber on the road.

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For any of you curious to how the centering of the rear wheel turned out.

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[oatnet]

NIce to see this coming together! What model/diameter Maxxis tire are you using?

-JD

[StudEbiker]

Thanks! They are Maxxis 26 x 2.4 Holy Rollers. Yeah, this build has been slow for sure. Luckily it's the second build so I haven't been in a rush, but it has not been the most cooperative thing I've ever put together for sure. I should have the bracket for the rear BB7 tomorrow and hope to make some good progress this week on it. I think you probably saw this picture over on the battery thread, but just in case you haven't:

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[StudEbiker]

Some progress.

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[Microbatman]

Nice work.

Did you have to grind down the rear disc brake adaptor/holder?

If so how did you do it?

[johnrobholmes]

Very nice colors coming together. A nice presentation for sure! Now we will wait to see if you can keep the batteries cleanly mounted


I bet it will be a hoot to ride.

[StudEbiker]

Nice work.

Did you have to grind down the rear disc brake adaptor/holder?

If so how did you do it?

I followed El Steak's instructions from this thread: viewtopic.php?f=2&t=13722

One thing I don't think he mentions in that thread though is that if you are planning on using a rear rack then it will be a good idea to use an 8" front bracket for the disc brake otherwise there are going to be interference issues.

El Steak made up a 6" bracket for me and sent it to me (Thank you El Steak!), but by the time it got here I had bought the Headway pack and realized the 6" bracket wasn't going to work. I ended up buying an 8" bracket locally and having a guy here in town that doesn't mind small jobs like that. He actually doesn't have a mill but his dad does so he took it home to have is dad take care of it for me. Which was pretty cool of him.

[grindz145]

very clean, nice!

[StudEbiker]

This build has given me a new appreciation of the work that people are doing on this forum. I mean jeez, I'm just putting together a bike and this thing has kicked my butt! I have kind of approached this bike as a test bed though and using it for "on the job training" so to speak. For instance, I had never built a wheel before this bike, I can now check that off my list. I also learned how to build a truing stand.

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Now I have bought a battery that is going to need to be tinkered with. It has a known to be bad BMS so I am going to run without a BMS but it is still going to need some rewiring. I may be seeking help with that in the future.

I've learned a whole heckuva lot about the Infineon 9fet controller and I am looking forward to reprogramming that little jewel in the near future. I don't know about using the regen, but I am planning on opening up the max amps on it and seeing what happens. Speaking of the Infineon stuff, man you guys that open this stuff up and just know how to start tinkering with it blow my mind! Thank you all for sharing what you know with the rest of us on the forum!

Anyway, hopefully I am on the downhill side of this build. It has been interesting and very educational and I am SO glad that this was not my first E-bike project or I may have gotten very discouraged. Compared to putting on the Aotema kit from HIghTekBikes and plugging in their battery this build has been a major undertaking. I really want to thank Oatnet for giving me a really good deal on this frame and parts, also Zoot Katz for his rear 9C build thread that provided good info for me that saved me alot of work I'm sure, and El Steak's work with this kit has been very helpful as well. I'm sure there are others that I've learned from as well and thanks to you too.

[StudEbiker]

Well as promised I am seeking some advice regarding the removal of the BMS from this Headway pack.

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The two wires that are heat shrinked together at the top of the board are the wires running to the batteries, the two wires at the bottom of the board run to the power outlet and charging port.

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So do I just need to connect all the black wires together and remove the board to run without BMS?

[mikeross]

Studebiker: Very nice work on your build! I am also going to make an attempt at building an S-750 with a 9C rear motor and the same battery/rack you are using. This will be my first build, so hopefully it won't be too tough. You are ahead of me right now - mine is all sitting in boxes in the garage. I do have an inquiry in to Ping about a BMS and charger for the Headway. I'll let you know if Ping has a solution, plus cost. Hopefully, someone can confirm your idea regarding the best way to cut out the existing BMS. By the way, I live in Oregon, too, up by Salem. I'm anxious to watch your build progress!

Mike

[StudEbiker]

Studebiker: Very nice work on your build! I am also going to make an attempt at building an S-750 with a 9C rear motor and the same battery/rack you are using. This will be my first build, so hopefully it won't be too tough. You are ahead of me right now - mine is all sitting in boxes in the garage. I do have an inquiry in to Ping about a BMS and charger for the Headway. I'll let you know if Ping has a solution, plus cost. Hopefully, someone can confirm your idea regarding the best way to cut out the existing BMS. By the way, I live in Oregon, too, up by Salem. I'm anxious to watch your build progress!

Mike

Thanks Mike. This project has been a slow go, but I have learned so much along the way. What I have decided to do on the battery pack is just keep the amps below 35 and run it stock. Based on what I have read and what some have told me this BMS is good to around 35 amps. If you are going to be using the Infineon controller there is a pretty slick way to wire it up to the key switch on the EVC battery pack which is discussed in this thread: viewtopic.php?f=2&t=16881. I am hoping to make a great deal of progress on the bike this week. All the parts are here now, just have to put them all together. I am taking my time and trying to get the wiring all nice and concealed and get it real clean looking. I had to accept JRH's challenge. I look forward to seeing your build too.

[DervAtl]

Nice work StudEbiker. I'm gonna take a look at El Steaks thread on the rear brake. I'm builing a TF too. If the weather ever gets better here, I'll post some pics. I seriously thought about the 9C, but in the end went with a BMC. Unfortunately, I had to send it back after 2 days due to a faulty clutch. It was a V1. I went ahead and upgraded to the V2. Hopefully better luck this time.

I'll be watching for more pics!

[StudEbiker]

Had a maiden voyage on this beast of a bike today! I think I am going to call this bike, "If it's worth doing once, it's worth doing three times." It fought me all the way but now that I am getting pretty close to being done with it I have to say I am pretty pleased with how it has turned out.

I had to take JRH's challenge (planned on being as clean with the wiring as I could anyway ) I still have a couple of things to work out, but here is where it stands right now. The covering over the rack mounting bars is some heavy gauge vinyl type stuff I had laying around. I ran out of black zip ties. The white ones will be replaced soon. All the connections for the throttle and the wheel are wrapped in there. I ran the controller power wires out of the opposite end of the controller. Minor modification compared to some of the things that happen on the Sphere, but I feel like that was a big thing for me to do. I am not terribly comfortable with the electronics and opening this stuff up. The old saying about a little knowledge being a dangerous thing comes to my mind all the time when I am tinkering with that kind of stuff. The key switch on the battery powers the controller only. Which is kind of a good news bad news situation. The good news i I don't have a huge spark in the switch every time I power on, the bad news is I always have two hot posts on the bottom of the battery whenever I take it out of the rack. Shouldn't be a big deal, but Murphy can show up when you don't expect him. I put the andersons between the controller and the battery so I can plug in the watt meter and maybe parallel my other battery for longer rides.

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The bike rides well and the dual discs should be nice...not to mention a front suspension. I still need to put the grips and computer on it and get a good light. I am also going to pad the battery rack some because the battery does flop around in the some. That will drive me crazy. I am looking forward to getting to know this bike, and it just started getting real nice weather wise here so hopefully I'll be racking up many miles soon. My first impressions of the motor from the short test ride I took today is that this motor climbs well. I was a little concerned about having all the weight on the rear wheel, but it really didn't seem to handle much differently than my front hub rear battery bike. Thanks for all your help everyone, this forum ROCKS!!!!!

[oatnet]

NICE!

[mikeross]

Veeeerrry Nice! I hope mine turns out half as good. It is very impressive the way you were able to clean up all the wires and cables. It is good to see that such a neat build is possible. Keep us up to date on the particulars such as top speed, miles per charge, and how that BMS holds up. By the way, I'm waiting on a cassette for the rear motor from ebikes.ca plus a BMS and charger from Ping, then I'll be tackling my own build. Great bike!

Mike

[StudEbiker]

So after a couple of longer rides I am truly amazed at how smooth this bike is. The big tires and the front suspension make a huge difference!! I thought my last bike was quiet and rattle free, but this one is like riding on a cloud!! There is one pretty brutal set of railroad tracks that I have to cross a few times a week and on the Trek I had to slow to a walking pace and they would still rattle my bones. I took them this morning faster than I thought I should just to see what it would feel like and I was startled at how smooth and rattle free this bike is. I put a small piece of the closed cell foam between the battery and the rack from the battery kit packaging and it stopped all flopping of the battery in the rack. I need to get a chain guard fro the rear stay but other than that (and the freewheel) there are really no noises coming from this bike. AMAZING!!

[chroot]

I have a question, I have same kind frame and everything like your bike. I am in process buy a 9c kit and Can I able fitting the 7 speed freewheel on 9c motor hub - Freewheel from ES sale http://endless-sphere.com/forums/viewtopic.php?p=164988#p164988

Let me know, Lastly Whats the volt capped on E-Bikekit controller 36/48v, What if I have 66 volt norminal and will it blow up the E-bikekit controller?

[ambroseliao]

Hi chroot,

Despite my signature below, I'm still running the front hub and plan on switching to the rear motor shortly. I ordered my rear e-bikekit.com motor with the 6 speed freewheel. In practice, I NEVER use any gear lower than the top 3 in my riding to and from work. I don't have any huge hills, but there are a couple of moderate hills and I usually don't even drop down 1 gear for those with the e-bikekit motor.

I wanted to chime in on the max voltage of the e-bikekit controller. The caps inside are rated for 68V maximum so with a fully charged 66V battery, you will probably blow the controller. I am now running at 48V nominal and my setup is at 54V fresh off the charger so the standard Infineon controller from e-bikekit.com handles that just fine.

Ambrose

[StudEbiker]

I agree with Ambrose about the freewheel. 6 is too many if you ask me. Is there such a thing as a five spd freewheel? If there is, I think I would have gone with that because I think I would not have needed to spread the rear stays as much as I did. I'm also going to defer to Ambrose on the controller question as that is not my strong suit. I think I understand what he is saying though and I agree with it.

[vanilla ice]

I just bought a cheap 5 speed from niagara. Or here is another that looks a little nicer..
http://store.icyclesusa.com/fw-multi-su ... p7579.aspx

[chroot]

Thanks for the info regard freewheel, I guess, I will go for 5 spd freewheel and I might go for 15 cells LiPo with hot charged set at 4.1 x 15 cells = 61.5v as you mentioned the Ebikekit's controller's capacitor rated at 68v. Should it be allright? (I'll ask Methods before doing it with the 15 cells LiPo)

I was gonna order a 9c kit today but have no time. I probably going do it by tomorrow.

-c