Old School Marin Build

[billsy]

I had many problems with 40 amps. on my bmc it would give a hmmmm. in a graling tune. It finnaly got a c.a. turn it down to 25amps. I would ask how many amps a 9c can take a solwer high torque would take more ? If using on hills and that is it use or a tailor not speed. I think if you over amp. it will not only over heat but it has some rambling inside the motor hmmm. Of coarse I just made that of but I do beleive it ? I do hear it. Yes ?

Hmmm is your BMC geared or direct?
The motor I'm using at the moment has never skipped a beat at >40 amps. According to my CA it pulls 45 amps when accelerating and occasionally reaches 65 amps. I'm not sure why it goes so high with a 40 amp controller but it does and I've not had any problems in 2 years. I'm pretty confident that the new 9C 2806 will be ok but I'll check with Justin anyway.

Thanks

[billsy]

Quick update

The batteries are still en route from BMSBattery (Ordered Sept 28).

Ping BMS and charger were shipped on Monday Oct 11.

9C 2806 rear disc motor kit inc 40A controller ordered from ebikes.ca yesterday Oct 14.

DC-DC converter and SM connectors received from member Lyen thanks very much.

Back soon

[billsy]

Yesterday morning I was pleasantly surprised to find the FedEx man walking up the drive with what I instantly recognised as a hub motor kit. I have to say that is an amazing service from both ebikes.ca and FedEx. I only ordered it on Thursday morning (UK time).
 
Also the Headway cells arrived from BMSBattery today. That took exactly three weeks
 
I'll get some pictures up later.

Edit: The Ping BMS and charger also arrived today.

Here's the 9C 2806 (10x6) Rear kit from ebikes.ca

[billsy]

And here's the little beauties

I've checked the voltage of each cell and they're all between 3.334 and 3.35

[knoxie]

Hey Billsy

Thats super fast service!! hope you arent stung too badly when the import duty bill pops up in a week or so always the bummer when ordering stuff from overseas unless you get the vendor to stretch the truth a little ahem!

So lots of nice toys to play with there you should have it all up and running OK I am sure, you have a bit of crimping to get the battery pack together and I suppose that is the main job, the rest should be nice and simple.

Looking forward to seeing what it turns out like, the motor looks sweet they have a nice finish on them I will certainly be considering one of them in the future.

Keep us posted

Knoxie

[billsy]

Thanks Knoxie

Yeh those import duty bills are a pain. The cells were marked up as a gift but I forgot to ask Justin at ebikes to do the same so may get a bill.

I think my next task will be to assemble the pack on the bench and see if it balances a few times. Any ideas what I can use to do a load test?

[knoxie]

Hi Billsy

Even if you get it sent as a gift they still tax you over 18 dollars! Hobby King send it as a gift and you can select how much its worth so you can skirt the UK tax laws if this what you want to do not suggesting you do this of course

All your kit is looking great!! I wouldnt worry about checking those cells check them on the bike best load you can put on it hope you got a few spare cells in case? keep the pics coming going to be a nice build this one

[billsy]

Made a little progress today. I have two torque arm's cut and one of them mounted. Big thanks to Kevin ( Member: gwhy) for cutting the profile out for me that would have took me weeks . I have to say I'm getting pretty damn good at filing those 10mm slots tho.

I modelled them using the Sketch Tracer workbench in Catia (during my lunch break ) it enables you to scale a picture and then overlay a sketch. I'm really happy with the result.









P.S. I didn't get an import duty bill yet

[knoxie]

Hey looking awesome! very nice indeed! did you get it laser cut? or CNC? or water jet maybe? be interested to know how the battery build is coming on.

[gwhy!]

Very nice,
Looks a very neat way to to beef up the dropouts. Looking forward to seeing it all come together.

[billsy]

8)

Hey looking awesome! very nice indeed! did you get it laser cut? or CNC? or water jet maybe? be interested to know how the battery build is coming on.

No he used an angle grinder with cutting disc to cut them out and then his Dremel to tidy up. Is this correct Kevin?

I'll be working on the battery tonight so I'll try and get some pics up later. Just need to get some cable.

Ordered some 26 x 2.2 Continental Race King tyres today. £20 delivered for the pair off fleebay. Also ordered some liners to keep punctures to a minimum.

[gwhy!]

8)

Hey looking awesome! very nice indeed! did you get it laser cut? or CNC? or water jet maybe? be interested to know how the battery build is coming on.

No he used an angle grinder with cutting disc to cut them out and then his Dremel to tidy up. Is this correct Kevin?

Yes , 2mm wide cutoff disc on a grinder ( would have been quicker if I had a 1 or 1.5mm cutoff disk )for the big straight cuts then a small cutoff disk on a dremel for the smaller cuts then a milling bit in the dremel to tidy up the small cuts, and to finish off a small sanding drum on the dremel .

[billsy]

8)

Hey looking awesome! very nice indeed! did you get it laser cut? or CNC? or water jet maybe? be interested to know how the battery build is coming on.

No he used an angle grinder with cutting disc to cut them out and then his Dremel to tidy up. Is this correct Kevin?

Yes , 2mm wide cutoff disc on a grinder ( would have been quicker if I had a 1 or 1.5mm cutoff disk )for the big straight cuts then a small cutoff disk on a dremel for the smaller cuts then a milling bit in the dremel to tidy up the small cuts, and to finish off a small sanding drum on the dremel .

That does it, I'm getting a Dremel!

[gwhy!]

That does it, I'm getting a Dremel!

You know it makes sense..


Edit:
When using cutoff discs with a dremel ( well with any sort of tool really ) always wear goggles, the cutoff discs can shatter and fly everywhere.. Oh and also when grinding with a dremel and holding everything in your hands dont forget where the sparks are going its just to easy to set your clothes on fire

[billsy]

Here we go. The basic pack is assembled.

I'll be on a cable hunt tomorrow afternoon!

[knoxie]

Looking good!! pack looks smaller than I figured it would be, looking forward to seeing it come together

Knoxie

[billsy]

8)

Looking good!! pack looks smaller than I figured it would be, looking forward to seeing it come together

Knoxie

Quite a bit of weight tho. It'l need to be secure on the bike

Connected everything up on the bench tonight just to test the components and the cycle analyst went up in smoke It's a direct plug-in one, so clearly nothing that I have done. I emailed ebikes and Adam replied within 10 minutes and said they will send a replacement today. They certainly know how to keep customers happy.

[knoxie]

sorry to hear you smoked the CA? silly question you did connect it the right way around? did you just connect the main power wires? not heard of them being smoked from new before, Justin stands right behind what he sells and is the most up front dealer around, you are in safe hands

[billsy]

:( sorry to hear you smoked the CA? silly question you did connect it the right way around? did you just connect the main power wires? not heard of them being smoked from new before, Justin stands right behind what he sells and is the most up front dealer around, you are in safe hands

It’s just a single plug which will only mate one way, can’t go wrong really. I will probably check the connections in the controller and the replacement CA when it arrives. I don't want to smoke another one

I'm making slow progress with the bike at the moment. Just waiting for some cable to arrive from Hobby King. I was under the impression that it would be coming from Germany but turns out to be shipping from China

I have managed to wire up the BMS and charge up the pack which balances perfectly after I did two shallow discharge/charge cycles. I'm happy with that. I'll share some pictures of the pack later. For now here's some pics of the completed torque arm installed with the 8.5mm spacer I had made. I also received a couple of 2mm rotor spacers which allow me to use my stock hydraulic brakes

Any comments or suggestions welcome.

[knoxie]

Very tidy!! looks really nice buddy thats going to be a stonking good bike looking forward to see the finished article with some video...before the snow comes its sure getting chilly out there...brrrr

Knoxie

[billsy]

Thanks Knoxie.

I have a question for the collective. I've been thinking that it might be a good idea to rig up some kind of ebrake switch to at least one of my hydraulic brakes. I've read quite a bit on here about reed switches and the mounting thereof and couldn't help thinking there must be an easier option. So I've been scouring the net for a Pressure Switch that I can add to the hydraulic line of my brakes. The only two that I managed to find are linked below but they are meant for cars/motorbike so I assume the activation pressure will be too high and they will be a pig to integrate.

Has this been done before on an ebike?
Can anyone point me to a more suitable pressure switch or more user friendly electrical switch setup?

http://www.surpluscenter.com/item.asp?item=11-2400&catname=electric

http://helperformance.com/store/product_info.php?products_id=3158

Many thanks guys and please don't hesitate to coment on this one.

Chris

[billsy]

Its been a while since my last post, apologies for that but the odd spare hour I get these days has been spent on the bike which hasn't left much time for anything else.

Any who, the bike is pretty much finished and I have to say, it turned out WAYYY better than I thought it would. The ride is so smooth, the weight is perfectly placed, the acceleration is very good and the top speed is just where I expected it to be at 30mph.

I know I know you need pictures.

Here's the battery box trial fit just after welding. You can see the head's of three bolts inside the box. They are the type of fasteners you would use to join kitchen units together. I also added spacers between the two boxes these were cut from a length of Aluminium tubing. Oh and not forgetting Loctite…lots of Loctite. There's also two screws on top where the bottle holder would normally be





Here's a slightly more mature battery



Here's the triangle box I fabricated for the charger socket/fuse and main switch. The switch is also a 40 amp circuit breaker part number W31-X2M1G-40 the waterproof switch boot is a standard item.






Here's the finished bike. I just need to spray the controller mounting plate and sort out the DC-DC converter for the Magicshine.
What do you think?

[knoxie]

Looks great!! well done on getting it all finished, would love to see some videos of you whizzing about on it as well, be interested to know how the batteries perform as well, really tidy work on such a great bike as well, you should be well pleased!!

Knoxie

[billsy]

Thanks Knoxie

Yes I am well happy with it. Its really solid as well, can't wait to get it on some trails. The battery performs fine. I've used it every day this week for my commute which is 10 miles round trip which it manages flat out, no problem. I'm not sure exactly how much juice is being used as I'm having problems with the replacement Cycle Analyst (which Justin is addressing of course). I will try and get some vids up soon.

[knoxie]

Hi Billsy

Yes its a great looking machine mate and I know how well those bikes ride too so I bet you are having a blast, looking forward to seeing some videos of it on the move, it was cold today mind, i have been using my normal bike to get to work a I am trying to loose a bit of xmas weight gain! ha ha, weekend looks better, must dust the electric BMX down for a spin!!

I am sure that Justin will sort your meter issue, you have a BMS right? so at least your not going to drop your cells too low? thanks again for sharing the pictures, its one of the tidiest machines I have seen in ages!

Knoxie