I've been a member for a while and have made a few posts here and there before but I haven't had much to contribute. My build has been slow since I haven't had much time at all to devote to it what with work and family commitments. My biggest mistake was instead of buying a working bike I decided to buy components and assemble them, this meant I had to learn about such things as headset bearings and the ins and outs of disc brake mounts for example, with quite a few mistakes along the way
This bike wouldn't have happened if it wasn't for this forum
Here she is in all her glory. I'm definitely going for the Stealth look here. Still some finishing to do but I was so close I just had to take it out for a spin Specs:
Lyen 12Fet sensorless controller
Orange Patriot frame (Don't know the year but maybe 2002-'04)
Marzocchi Bomber 888 RV forks
Halo SAS 24" front rim
Hope M4 front brake & 203mm rotor
3x 6s 5000mAh Turnigy Lipos in series for 18s (75v)
I made the rear dropouts from 10mm steel. Took me almost 2 days with a grinder, drill, and file to shape them to match the dropouts. They sit snuggly into the frame and don't need anything else to secure them apart from the rear wheel nuts.
The battery box is aluminium angle and fibre board. More of a mockup really, fibre board is just cheap and easy to work. I intend to replace the fibre board with Carbon sheet for looks. With that shock position there was no chance of putting the batteries inside the frame triangle. The bottom of the box is fibreglass and is shaped to sit over the top tube, this spreads the battery weight into the frame and allows two of the packs to sit on either side of the tube a bit lower down. I was aiming for stealth so the sides of the box hide the controller and some of the wiring. Its is big enough for me to double my battery capacity, maybe triple it.
I'm pleasantly surprised. So far I've only had 6 runs on it. Only one of which was to LVC (deliberately). I'm logging distance, max/average speed, and mA put back into the packs when charging. This allows me to get some rough figures for efficiency. Flat out it'll do 42mph and feels super stable. Riding for economy with plenty of light pedalling at 17mph I can do 25miles. It pulls up hills very well. So far no CA but I'm thinking of making my own equivalent with an Arduino, just for the challenge.
This is at 18s with the controller set to 30A. Soon I'll up it to 45A just for a laugh Future
Carbon the battery box
Cut down the bars - they're so wide my arms hurt!
Paint the frame
Tidy up the cables and lose the ghetto duct tape look
Switch for 'legal power' before I get lifted by the cops
This has been a lot of fun and I don't think this will be my last build!