First E-Bike build - Full suspension, geared & DD motor

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Need to fab up a "dashboard" now!

Going to be putting the bike back together today, I need some excercise.

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Yes

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Got most of the work done to get her back on the road. Ending up using the 9fet amped controller and hid it away in a underseat bag. Also cleaned up more wiring. Just need to work on the battery box now.
Took it for a short ride with a low batt, its definitly faster than the geared hub, but also louder. Mostly during accel, once up to speed its quiet.

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Wow just took this on a 25 mile ride (63* here woot!)

A couple things I noticed is the DD is much more power hungry than the geared. At least it seemed that way, although It could be that I was riding in 20-25 mph winds, and did some trails in there. The volt meter is necessary because I noticed with DD, you can only go so fast for a certain situation. For example, riding directly into the wind, I could do about 24 mph, but more than half throttle did nothing to increase speed, and just dropped the voltage on the pack, creating heat on the controller. So basically I just find the "sweet spot" on the throttle where I can keep cadence, but not start dropping the pack volts too much. I put some Andersons on my volt meter so I could monitor every couple miles, but I need to permanent mount that as I drained my battery to 3.0v per cell, which isn't the end of the world but I don't like going that low. Long story short I unplugged the batt and pedaled the last 3 miles home. It was pretty tough, that extra weight and magnet resistance is no joke lol, I was wishing my geared was back on there, but got some serious leg exercise, so that's ok. I would rather get the exercise then ruin my batt. Also did some more taping up and wiring on the batt pack.

Oh yeah, also I like the new fork, much better handling and feel than the suntour.

Also really like the DNP freewheel, it sounds way better than the old one, much more solid, and the 11T gear mates up well for 25mph pedaling.

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Dear god someone help me!

I just ordered 2x of the same rotors, but in 203mm size. That should solve my rear clearance issues, improve the brakes overall, and keep the same look

[kfong]

I was out riding as well in this remarkably warm day. Should of been kiteboarding at metro though. I stopped by there since I was in the area and watched some of the kiteboarders having a blast. I had a late start so I ended up going trail riding instead. My ride was cut short near the end by a flat tire. Damn, going tubeless this year. Tired of all the flats.

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Damn! I rode into metro and checked out the kite boarders too! Im surprised we didn't cross paths!

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Designed and cnc'd my dashboard plate. Fits nice and snug. Going to have a couple switches under the voltmeter. Maybe a lights and ignition. And further down the road maybe a 3way switch for off>48v>72v

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Just did another 20 mile journey. Going to need to add more amp hours!

Awesome weather here. Painted the dash wrinkle black and wired up the voltmeter. Pretty quick hot off the charger.

My new 203mm disk rotors came yesterday. REALLY need to get my back brake going. Riding with only the front sucks and is risky.

Forgot to mention, this time around I used velcro strap for wiring and cable that I got at west marine. Works great, doesn't scratch bike, and is easily removable and reusable.

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Decided i need to upgrade my charging situation. The AC6 chargers work fine but charge max 2.5 amps, when I could be safely charging at 7.5. Think I am going to take kfongs advise and pickup a hyperion 1420i.

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Old vs new rotors. Should be able to get them on tomorrow if I can find some adaptors locally.

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Tore her down again. Ordered caliper brackets for 203's. Made a rear spacer by cutting apart an old 160 rotor. Put about 100 miles on the amped bikes dd hub and noticed a lot of the spokes are loose. Was making some serious racket at low speed. Going to go through those with a wrench. Also pulled the freewheel to add some anti seize. I need to find a good way or connector to attach and detach the controller during wheel removal. Cutting it each time is getting old. Ideas?

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Picked up a set of brand new avid BB5 calipers from my LBS. They were take offs from a Giant, and got them for a good price. Should be a nice upgrade from the tektros to grap the 203mm rotors. Stalled on the project for now until the caliper adapters get here. Should be Fri or Sat. BTW if anyone want one of the "dashboards" seen in the above pics, I cut 4 of them on the CNC, 1 has the hold for the voltmeter, and the other two are blanks, with a 40mm hole for attaching to the fork cap.

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Lithium grease/most any automotive grease works fine as does anti-seize. You don't need much. Get some oil in your freewheel and put more in now and then if you want it to last. Thicker stuff i.e. SAE30 or 20-50 ect lasts longer and if you get enough in it can quiet things down a bit. See that your axle nuts fit flat on the dropouts when things are tightened. Mine did not so got better quality stainless nut and lock washer. Nylock/aircraft nuts werq also pay lots of attention to this area for awhile loose nuts trash your bike. It's the little details that make things run smooth and last for awhile.

Really good advice. I put some mobil1 15w-50 motor oil in the free wheel and it quieted it WAY down, and it definitely turns easier now. It also flushed out some crud that was in there. Thanks for the tips biohazardman.

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Finally got my caliper brackets and time to finish the big brake upgrade. It's amazing to me that I completely stumped 6 LBS as to what I was doing and the parts I needed for the brake upgrade, when I figured it out in minutes on ebay. Yay for disk brakes on a rear 9c!! Also picked up a new underseat bag that is larger for the controller to give it some breathing room. Also bought a spoke wrench to tighten up the DD hub spokes, some of them were very loose! Oiled up the freewheel and puts lot back together. Also I think I figured out the hall sensor connector... the idea came after making a bunch of cat6 cables yesterday .. see pic!

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Ended up solidering the hall and phase connections. Also brought out my gangsta tool and completely redid the battery pack. Added my remaining 4 packs and relocated the brick from under the shock mount. If the lower shock mount fails it will collapse into foam instead of lipo now! Put Anderson's on all packs so they can be reconfigured. Used some home depot neopreme foam for weather stripping to isolate the packs. Worked VERY well and is cheap and sticky! Right now running a 12c5p giving 50v hot and 13 amp hours. Going to run her 25 miles tomorrow. Just balanced all 10 packs individually. She's ready to rip.

[dogman]

Sigh, another guy with naked lipos strapped to the bike up and running.

I'm such a nag, but sheesh, get a side panel on that thing. At least, tape some coroplast political sign to the sides. One failed kickstand and you might have a lipo fire when the bike falls over.

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That's why I don't run a kickstand

Just messin, I'm actually headed up to the sign shop today to CNC cut some .063" aluminum panels for the sides. They also have coroplast there too, so maybe i'll make a buffer of coro between the batt's and aluminum. No worries dogman, I am taking care of it, your sighs will soon be that of relief. I also NEVER store the batt's on the bike. As soon as it comes into the house, the batt. gets detached and put into a steel box.

On another battery related note, I picked up a Hyperion 1420i charger yesterday, so I can charge 14 cells at once saftely. Tried it out using a fully charged marine battery and it works great! I need to find a good 24v 20 amp power supply now so I can charge my bank fast. Now to parallel the balance taps.

[Diamondback]

great choice for a charger !

i have a Hyperion EOS0720i SD3 for my RC stuff, and it will be used to charge my next ebike battery too.

for a Powersupply, im using a Meanwell SE1000-24. its a little on the noisy side (its designed to be a server supply)
and it's puts out 24V at up to 41.7A it draws 17.5A from a 110V socket and 10A on 240V.

Jason.

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This ones for you dogman. Still need a top plate but its a start.

[GrayKard]

On another battery related note, I picked up a Hyperion 1420i charger yesterday, so I can charge 14 cells at once saftely. Tried it out using a fully charged marine battery and it works great! I need to find a good 24v 20 amp power supply now so I can charge my bank fast. Now to parallel the balance taps.

Have you looked at EPbuddy.com? They have a good selection of real meanwell power supplies.

Gary

[kfong]

Looking good Joe, just got back from a snowboard and ski trip out in South lake Tahoe. Monday was one of the best days this season. Wasn't a very good year for snow.

Missed out on the record high temps here. Need to get my ass in gear and get the Motobecane bike wired.

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Just purchased 2x 12v 47amp HP server power supplies to feed the Hyperion. Refilling the lipos has been the most tedious and time consuming step, so this charging upgrade is overdue. Will have to do some work to put them in series (24v) , but then i'll be able to max out the hyperion if need be.

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More battery work completed

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Server power supplies arrived and have begun working them into a series config.

Also just ordered a Lyen 12 FET extreme controller to have on hand.