Well, I missed the 1000 mile mark, so here's the 1147 mile
update. Two months in, it's getting colder, and I'm still commuting 4 days a week!
Salsa Gordo rims installed, 35mm wide vs. the old 24's. Much less sidewall flex at 40psi with the big fat 60mm tires, and less fear of tacoing. And they're full black sidewalls, the bike looks much meaner now.
Just found this nasty cut in my tire! For two weeks I've been wondering what that bump in the ride was, but my fender hid the damage. Had to boot the tire from the inside, & filled the gap with silicone, but I think it's new tire time. I've definitely hit mystery debris in the dark at speed...
New Controls: Ditched the left-side thumb-throttle and went with the Magura twist & Oury grips. Love it! I had to bend the Alfine shift levers down to clear the throttle. I'm not using the Cruise Control any more, so that's going to go away. I hooked up the Cycle Analyst "current throttle" option, which works but has poor response (slow, with overshoot...) as documented here: viewtopic.php?f=2&t=31518&start=15#p470572
Battery Pack: Reconfigured from 12S4P to 18S3P, adding one 5AH pack and bringing the pack up to 1026 WH. I've always wanted to put the packs in the frame triangle, but everyone kept commenting on how stealth my bike looks, not like an electric bike at all, so I decided to stick with the pannier approach. The new pack is narrower & taller, which wags the tail less when it's strapped tightly to the rack. A few mods to the rack quieted up all the rattles, now the bike just makes balloon tire noises when I hit bumps!
I ditched the fuse block & went with soldered blade fuses, and located the kill switch between the 12S and 6S packs, and also used it to interrupt the charger plugs. This way, one switch kills power to the controller and charger, should anything go wrong.
(yes the AH numbers at each plug are wrong, should be 15AH)
Two charge plugs & battery switch:
Battery pack in the right pannier:
I've been keeping track of energy usage, on about half of my trips. WH/Mi is at the controller, and MPG-E is at the wall. A lot of the variability is due to winds, and all of the data above 24mph is with the 18S pack.
All photos posted in this flickr set.Performance:
30mph is my new minimum cruising speed, with a 10mph headwind. I've had a few good tailwind days & cruised at 36-38, with some short stretches up to 42mph on the flats. This is with 18S and a 20A current limit. I don't have a thermocouple set up yet, otherwise I'd be tempted to keep pushing the amps up. Some cars still pass me, but I keep up with traffic much better than before.
I'm having some wheelspin problems in the rain from a start. Part of this is FWD, and weight distribution, but the most annoying part is the throttle interface. The Current Throttle is better than the standard throttle, but it's just not right. A long delay followed by a surge, it almost put me down at an off-camber stoplight, the wheel spun & took off sideways, I barely got a foot down in time to save it.Hopes & Dreams:
-Brake light, for playing in traffic. Maybe I'll even do a big LED array like this:
-SpokePOV kits received! Just need to sit down & solder them up, and figure out waterproofing. Stoked!
-Arduino Throttle Interface. Just received my Uno to play with, I'll probably package it all up with a Nano once I know what I'm doing.
-Traction control using hall effect sensors on the brake discs, to get multiple pulses per rev. Lots to learn here! Sure, RWD would eliminate this problem, but I'm having fun with what I've got
-Studded tires for the coming ice
-Hand guards for warmth, with integrated turn signals?