The Falcon, My 1st Build

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The Journey Guy   1 kW

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The Falcon, My 1st Build

Post by The Journey Guy » May 14 2010 6:39pm

Hello all. With the help from members here, and with countless hours reading and studying this forum, I am pleased to have completed my first electric bike build. My 1st ever e-bike was a Currie E-Zip, which I used for 2 years. But as I get older, I get heavier :( , and it was time for me to get a more powerful bike. After shopping around, I figured out that for me and my size, 6'-1" 220lbs, I was going to have to build one myself to get it right.

This forum gave me the information and motivation to make this bike, which I have named "The Falcon".

Most of the tech information is in my signature already, so I won't repeat all that. The battery packs are in the hard sided panniers which I had on the E-zip, and the controller is inside the rear trunk.

So, let's get to the photos, eh?

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Here she is with the Croozer cargo trailer. With that 5303 I don't even notice the trailer behind the bike.

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Last edited by The Journey Guy on May 20 2010 1:19pm, edited 2 times in total.
'The Falcon' - 2009 Trek 7000
Build Thread - Revision 2: http://endless-sphere.com/forums/viewto ... 25#p285825
Crystalyte 5303 Front Hub with 700c wheelset
Crystalyte CT4840 48v40a Controller
Cruise Control
Cycle Analyst
Nextar GPS/Stereo
48v10ah Headways

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The Journey Guy   1 kW

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Re: The Falcon, My 1st Build

Post by The Journey Guy » May 14 2010 6:42pm

And yet more photos:

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Just some random guy who happened by and offered to model the bike.... :roll:

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What a ham!

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End of another day's ride....
'The Falcon' - 2009 Trek 7000
Build Thread - Revision 2: http://endless-sphere.com/forums/viewto ... 25#p285825
Crystalyte 5303 Front Hub with 700c wheelset
Crystalyte CT4840 48v40a Controller
Cruise Control
Cycle Analyst
Nextar GPS/Stereo
48v10ah Headways

drewdiller   100 W

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Re: The Falcon, My 1st Build

Post by drewdiller » May 14 2010 7:54pm

Nice!

Heh, a setup that will haul ass at hauling cargo.

Did you do the shrink tubing on the Y/G/B Anderson connectors at the front fork? If so, what gauge tubing?

justadad1957   100 W

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Re: The Falcon, My 1st Build

Post by justadad1957 » May 14 2010 8:00pm

looks like a very nice ride :D
well done

Amonk   1 mW

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Re: The Falcon, My 1st Build

Post by Amonk » May 14 2010 8:12pm

Great looking build.Where did you get the hard Side cases (panniers)?

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wasp   10 kW

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Re: The Falcon, My 1st Build

Post by wasp » May 14 2010 8:52pm

i like it

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The Journey Guy   1 kW

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Re: The Falcon, My 1st Build

Post by The Journey Guy » May 15 2010 7:45am

drewdiller wrote:Nice!

Heh, a setup that will haul ass at hauling cargo.

Did you do the shrink tubing on the Y/G/B Anderson connectors at the front fork? If so, what gauge tubing?
Thanks!! Yep, I did the Andersons, and used 1" Shrink tubing to cover the 3 connectors side by side. Just barely fits.
'The Falcon' - 2009 Trek 7000
Build Thread - Revision 2: http://endless-sphere.com/forums/viewto ... 25#p285825
Crystalyte 5303 Front Hub with 700c wheelset
Crystalyte CT4840 48v40a Controller
Cruise Control
Cycle Analyst
Nextar GPS/Stereo
48v10ah Headways

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The Journey Guy   1 kW

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Re: The Falcon, My 1st Build

Post by The Journey Guy » May 15 2010 7:46am

justadad1957 wrote:looks like a very nice ride :D
well done
Thanks much!! It does ride well, but at higher speeds, being a hard tail, it's really rough on the ole back. That's why I got a Thudbuster to go on it next week. We'll see if all the hype is worth it. :wink:
'The Falcon' - 2009 Trek 7000
Build Thread - Revision 2: http://endless-sphere.com/forums/viewto ... 25#p285825
Crystalyte 5303 Front Hub with 700c wheelset
Crystalyte CT4840 48v40a Controller
Cruise Control
Cycle Analyst
Nextar GPS/Stereo
48v10ah Headways

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The Journey Guy   1 kW

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Re: The Falcon, My 1st Build

Post by The Journey Guy » May 15 2010 7:49am

Amonk wrote:Great looking build.Where did you get the hard Side cases (panniers)?
Appreciate that! I got the panniers on ebay about a year back. I've looked but can't seem to find out anything about them except they were made about 15 years ago, by a company which seems to still be in business. I emailed them several times about the panniers, but they will not answer. So.....
'The Falcon' - 2009 Trek 7000
Build Thread - Revision 2: http://endless-sphere.com/forums/viewto ... 25#p285825
Crystalyte 5303 Front Hub with 700c wheelset
Crystalyte CT4840 48v40a Controller
Cruise Control
Cycle Analyst
Nextar GPS/Stereo
48v10ah Headways

kfong   1 MW

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Re: The Falcon, My 1st Build

Post by kfong » May 15 2010 9:00am

Nice clean build. Looks like a great setup for cross country trips.

deVries   1 MW

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Re: The Falcon, My 1st Build

Post by deVries » May 27 2010 11:23pm

The Journey Guy wrote:
justadad1957 wrote:looks like a very nice ride :D
well done
Thanks much!! It does ride well, but at higher speeds, being a hard tail, it's really rough on the ole back. That's why I got a Thudbuster to go on it next week. We'll see if all the hype is worth it. :wink:
When you get a chance, please give us a performance report on the Thudbuster. How heavy is it?

Thanks!

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vodka   100 W

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Re: The Falcon, My 1st Build

Post by vodka » May 31 2010 2:57am

nice bike, whats the top speed with 5303 @ 48V on 700c?
-> Current bike build thread:
Crystalyte 5304 rear 26" / Cycleanalyst 2.2 / 48 Volt 30Ah Ping Battery 1.5Kw/h/ Crystalyte 4850 Controller 18 Fets / over ~17000 km / Gear ratio of 1 : 4.82 view images

Old bike: Crystalyte 5304 rear 26" / Cycleanalyst / 48 Volt 30Ah Ping Battery 1.5Kw/h/ Crystalyte 4840 Controller / over 1000miles

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DervAtl   100 W

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Re: The Falcon, My 1st Build

Post by DervAtl » May 31 2010 12:23pm

Well done! That's a really sweet ride and I love all the detail. What do you use the trailer for?

I would love to find those panniers. If you know the name of the company, please post.
Darryl
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Held back a gear   1 µW

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Re: The Falcon, My 1st Build

Post by Held back a gear » Jun 24 2010 7:55am

Great job on the bike JG.
I got my "Thudbuster" last year, and I am glad I did. I't does not make up for the lack of a rear suspension (of course), but it takes the edge off all those little hits. I think I would buy one again-for the next bike.
Thank you for all the photos. I like to see the super clean wiring. I hope to have my setup that nice.
Surly "Big Dummy" - leg power still
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Trek 5500 - (skinny road bike thiny-never did get used to it)

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ambroseliao   100 kW

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Re: The Falcon, My 1st Build

Post by ambroseliao » Jun 24 2010 9:38am

The Journey Guy wrote:Thanks much!! It does ride well, but at higher speeds, being a hard tail, it's really rough on the ole back. That's why I got a Thudbuster to go on it next week. We'll see if all the hype is worth it. :wink:
The Thudbuster is deceptive. At first, you'll not notice too much since it's so smooth, however, after a while, you realize that all those small and medium bumps that used to hurt your behind are suddenly much less obvious. I love mine. Be sure to use the right size thermoplastics for your riding weight which should include any additional items like a backpack, etc.

Ambrose
http://www.ebikes.ca/ is the best!

TidalForce M-750X, Tidalforce S-750 with Crystalyte HS3540, 1x TF iO-X Cruiser. E+ 1000W hybrid bike. ebikes.ca DrainBrain & Cycle Analyst meters. GoPro HD Hero2 camera. Bosch Fat Packs, 37V 10Ah LiPO pack. Turnigy Multistar batteries
My blog: http://ebikerider.blogspot.com
Remember LiFEPo4 HVC is 3.65V and LVC is 2.7V

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The Journey Guy   1 kW

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Re: The Falcon, My 1st Build

Post by The Journey Guy » Jul 03 2010 10:50am

I've finally recovered from my operations enough to go bike riding this morning. I took the opportunity to get some new photos of 'The Falcon' in it's Version 2 configuration. I removed the rear hard side panniers, the rear trunk, and the rack that I was using in the original build.

I am now running a rear rack from Currie that the E-zip and I-zips used to use. I got a hold of 4 empty battery cases that those bikes use, and have made them into 24v10ah Headway packs now. One on each side, run in series for a total of 48V10ah. That will give me more than enough range for my Mon - Fri commuting to and from work. I have two extra packs that I can carry in the trailer on weekends when I go out for my long rides.

This Revision 2 has saved me aprox 15lbs at the rear of the bike. Much easier to handle now, and just as much power as when I was running the Ping packs, which weighed twice as much as the Headway packs do.

The Thudbuster has proven to be all it's advertised! Like riding on a cushion, the difference is day and night. For anyone who has a hard tail bike, I would suggest you try one out. I think you'd use one from then on, they are that good!

On to the photos:


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Looks less bulky at the back of the bike now. I'm not too happy with the way the wiring is just sort of hanging there. If anyone has any suggestions on how to hide them better, I'd be pleased to hear your ideas. :)


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The new mounting system for the CA and my GPS/Stereo player. They are easier to read and reach to control while riding.

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Still a fairly clean build, IMHO.

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As I said, the Thudbuster is fantastic! Everyone should have one.

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Yep, I sure need to figure out a better way to route/hide the wiring. Suggestions are welcome! :lol:
Last edited by The Journey Guy on Jul 04 2010 5:01am, edited 2 times in total.
'The Falcon' - 2009 Trek 7000
Build Thread - Revision 2: http://endless-sphere.com/forums/viewto ... 25#p285825
Crystalyte 5303 Front Hub with 700c wheelset
Crystalyte CT4840 48v40a Controller
Cruise Control
Cycle Analyst
Nextar GPS/Stereo
48v10ah Headways

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Re: The Falcon, My 1st Build

Post by torker » Jul 03 2010 6:15pm

That looks good. The wiring would have to be trimmed to the same length first which would mean reterminating a lot of connectors. I like the woven nylon covering that is like a Chinese finger trap. You push it together and it opens up and then when you loom everything up you pull it to compress and ziptie it in place. I cheated on my recumbent and coiled my extra wire and added a sheet metal cover on one side and coroplast on the other. :mrgreen:
Dave When I die I want to slide in sideways yelling WooHoo what a ride !

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The Journey Guy   1 kW

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Re: The Falcon, My 1st Build

Post by The Journey Guy » Jul 03 2010 6:47pm

That's a good idea about the finger trap stuff. I wouldn't know where to get any, but you did give me another idea! I have some shrink tubing that is about 2" in diameter. I could cut a piece to length, and then cut it up the side to open it up. Then wrap the stuff around all those wires, zip tie the outside, and then hit it with the heat gun.

Almost the same concept you had. Thanks!!

TJG
'The Falcon' - 2009 Trek 7000
Build Thread - Revision 2: http://endless-sphere.com/forums/viewto ... 25#p285825
Crystalyte 5303 Front Hub with 700c wheelset
Crystalyte CT4840 48v40a Controller
Cruise Control
Cycle Analyst
Nextar GPS/Stereo
48v10ah Headways

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Re: The Falcon, My 1st Build

Post by amberwolf » Jul 03 2010 7:15pm

Probably any place that sells cable-making supplies would have the woven wrap. Especially places that do custom work for PC mods and car stereos.

Another thing that works well and is cheap is the ribbed pre-split cable housing used in car wiring harnesses. Same places ought to have that, as well as automotive stores; I remember that network cabling stores used to carry it around here, too, years back when I did that sort of work (when it used to be a mysterious thing the average person was afraid of doing themselves and would pay others to do for them).

Heavier duty versions of it in larger sizes and brighter colors are also used for underground fiber-optic bundles; I used to have a few several-foot-long sections of 2"-wide dayglo orange ribbed split housing, but I have no idea where they are now. If I did, they'd already be on CrazyBike2 covering the wiring *and* the bike frame. :lol:

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The Journey Guy   1 kW

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Re: The Falcon, My 1st Build

Post by The Journey Guy » Jul 03 2010 7:20pm

Yep, I like that stuff too. If you look close at the last photo, you'll see that I used some smaller diameter wire loom on the balance plug that comes out of the battery pack.

I just don't have any that is big enough to hide all the wires going to the controller.

TJG
'The Falcon' - 2009 Trek 7000
Build Thread - Revision 2: http://endless-sphere.com/forums/viewto ... 25#p285825
Crystalyte 5303 Front Hub with 700c wheelset
Crystalyte CT4840 48v40a Controller
Cruise Control
Cycle Analyst
Nextar GPS/Stereo
48v10ah Headways

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Re: The Falcon, My 1st Build

Post by ambroseliao » Jul 03 2010 9:53pm

I recently found the stuff here.

http://www.parts-express.com/wizards/se ... ID=2524701

It's called "Split Loom Tubing".

Ambrose
http://www.ebikes.ca/ is the best!

TidalForce M-750X, Tidalforce S-750 with Crystalyte HS3540, 1x TF iO-X Cruiser. E+ 1000W hybrid bike. ebikes.ca DrainBrain & Cycle Analyst meters. GoPro HD Hero2 camera. Bosch Fat Packs, 37V 10Ah LiPO pack. Turnigy Multistar batteries
My blog: http://ebikerider.blogspot.com
Remember LiFEPo4 HVC is 3.65V and LVC is 2.7V

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Re: The Falcon, My 1st Build

Post by ambroseliao » Jul 03 2010 9:54pm

They also had these which I found very interesting!

Cable Pants!

http://www.parts-express.com/wizards/se ... ID=2524701

Ambrose
http://www.ebikes.ca/ is the best!

TidalForce M-750X, Tidalforce S-750 with Crystalyte HS3540, 1x TF iO-X Cruiser. E+ 1000W hybrid bike. ebikes.ca DrainBrain & Cycle Analyst meters. GoPro HD Hero2 camera. Bosch Fat Packs, 37V 10Ah LiPO pack. Turnigy Multistar batteries
My blog: http://ebikerider.blogspot.com
Remember LiFEPo4 HVC is 3.65V and LVC is 2.7V

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Re: The Falcon, My 1st Build

Post by ambroseliao » Jul 03 2010 9:56pm

Sorry, last posting, I promise.

They also have "TechFlex" expandable sleeving.

http://www.parts-express.com/wizards/se ... ID=2524701

Ambrose
http://www.ebikes.ca/ is the best!

TidalForce M-750X, Tidalforce S-750 with Crystalyte HS3540, 1x TF iO-X Cruiser. E+ 1000W hybrid bike. ebikes.ca DrainBrain & Cycle Analyst meters. GoPro HD Hero2 camera. Bosch Fat Packs, 37V 10Ah LiPO pack. Turnigy Multistar batteries
My blog: http://ebikerider.blogspot.com
Remember LiFEPo4 HVC is 3.65V and LVC is 2.7V

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The Journey Guy   1 kW

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Re: The Falcon, My 1st Build

Post by The Journey Guy » Jul 04 2010 4:56am

Thanks for the links, Ambrose. Those cable pants have me stumped tho. Never seen 'em, and can't quite figure out what someone would do with 'em. :?

TJG
'The Falcon' - 2009 Trek 7000
Build Thread - Revision 2: http://endless-sphere.com/forums/viewto ... 25#p285825
Crystalyte 5303 Front Hub with 700c wheelset
Crystalyte CT4840 48v40a Controller
Cruise Control
Cycle Analyst
Nextar GPS/Stereo
48v10ah Headways

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Re: The Falcon, My 1st Build

Post by LI-ghtcycle » Jul 11 2010 10:06am

Very Clean! And I must say, very beefy tires too, if I didn't know better I would think those were 26" tires! 8)
Thank you Justin_Le for your selfless act of kindness! We all are in your debt.
Back on track E-Bronco! Now with Cro Motor Mid-Drive Goodness!
https://endless-sphere.com/forums/viewt ... 28&t=44997

Vision R40 w/3000w MXUS as mid-drive, NuVinci N171B rear wheel as transmission, Silent yet powerful, running 72v 11.6 ah (20s 18650 Li-Ion) to climb hills, tow trailer with zero pedaling when needed!

https://endless-sphere.com/forums/viewt ... 28&t=75247[/size]

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