Here are links to some of my earlier builds. I lost the link to my first build in '09, but that thing just handled so awful and had sla.
5th ebike build - GT Ricochet 450w - viewtopic.php?f=6&t=20801
3, 4th ebike build - TT Road racing Cdale 750w - viewtopic.php?f=6&t=19409
2nd ebike build - Giant rigid mtn bike 450w - viewtopic.php?f=6&t=17129
The first 3 pages of this thread are using a Mac hub on full suspension bikes. What a world of a difference in terms of performance, handling, and reliability. I was stuck on non-hub motors at first, but they really work well aside from making bumps worse.
June 2012 update - I just discovered that the 36v 11ah lifepo4 I got from Hyena last year is capable of >43amps peak. Voltage sagged 4v. I always thought it was limited to 21amps, but that must have been my controller settings. I built up the black khs with the 6 turn and this battery for my gf to ride last night. She says it's scary and only once pulled the throttle all the way up a hill I was encouraging her to open it up on. She accelerated from 15mph to 25mph+ while on the 8% grade......
This must be my 10th bike I've had electrics on now... I am finally riding real full suspension and it sure makes a difference. Only have done a mile so will report back later. It's using all the same parts as my previous two bikes this Fall - 6 turn Mac limited to 21amps on lifepo4 36v 11ah, or 48v 5ah lipo. It's not all that exciting but gets the job done. I will constantly be tweaking it, such as:
DONE- Get the battery in the main triangle!!!! (I hate the look and feel of it on a rear seatpost rack). It will fit JUST fit, clear of the crank arms, laid on it's side. Not ideal, but the best I can do with this frame. I still have my eye out for the perfect ebike frame....
DONE (rear)- Design a homemade mechanical lockout for rear and front shocks. The plan is to pull a lever on the bars which will hold the suspension stiff so I can stand and pedal hard without loss for nice acceleration or hill climbing on smooth road.
DONE - Add a pre-charge resistor so I don't get the spark when plugging in the watt meter. I normally can leave the battery plugged in if no watt meter since I can turn the controller off. http://mgm-compro.com/pdf/en-antispark-d230808.pdf
DONE - Run lipo more often. I got a 48v MW clone coming to bulk charge. Will likely double it to 10ah for 20 mile range.
Not needed - Somewhere down the line improve my torque arms, especially the drive side which is using 1/8" steel and only 2 small bolts securing it. The 6 turn doesn't have much torque, especially at my power levels ~1000w, so it's fine for now. _Update: On wet roads I stopped on some painted stop line, stood on the ground and pulled the throttle. Maybe it's because the battery is on a rear rack, but I still had enough traction that I couldn't spin the wheel. Come to think of it, the rear of the bike is really heavy. I can pull wheelies fairly easily because of it.
- Wearing winter clothing and sitting normal cuts my speed down from 28 to 25mph, but it really feels like more than that. I hate being non-aero. I will one day have an e-recumbent low/mid racer.