Another Genesis Build...

[ZOMGVTEK]

Parts are finally showing up, so its time to make a thread for the new build...

Genesis V2100 Bike
5404 Rear Hub
Lyen 12 FET IRFB4110PBF
Custom Farfle Swingarm
24S2P Turnigy LiPo


I intended on using new 4S packs, but ditched that idea since they are still out of stock in the US warehouse.
This is my same pack from my old build. I pulled it apart, and cycled each pack. One weak cell thats been replaced, one pack evenly discharging to 4.5AH, the rest 4.6-4.7AH (4.15-3.5V).


A member made this for me. It ended up needing a fair bit of work and fine tuning to get it to hold the packs firmly and safely, but works well.


I'm going to jam some foam in the open areas, and put the SMPS for the headlight in the middle. The batteries are held quite firm as is.










I initially had a block of foam to hold the batteries, but ditched the idea for the aluminum box that would take up less space.


I laser cut a new cover for my controller, so it fits better in the area behind the rear shock.

I intend on eventually making a 24S2P booster pack out of 4S Turnigy's to go on a rear rack.
The 12 FET fits nicely behind the shock, so I will just run it at its limits and see how it handles it before I move towards something like a built 24 or 36 FET controller.

[Farfle]

Bike looks good! The sheetmetal batt box is nice. Should be a real ripper once you throw a 24 fet on there.

[ZOMGVTEK]

It took a while, but the swingarm made it here and looks absolutely fantastic!
Thanks Farfle!

[Haste]

this build is so sick! Love it.

[nicobie]

Very nice battery box!

I'm sure they don't, but it looks like when you screw on the battery box side cover the screws will poke holes in the batteries.

Are you planning to get a better set of forks? I don't think I'd trust the stock one at 50 mph

[neptronix]

Are you planning to get a better set of forks? I don't think I'd trust the stock one at 50 mph

Mine came bent and had a ton of flex in it on my genesis bike.
It's a 5 pound steel fork.. most aluminum forks are about 5 pounds. They underengineered and skimped on the material. So i second this.. heartily

[Farfle]

Did that motor fit in the drops? I'm dying to know if it's the powdercoat or the machining.

[ZOMGVTEK]

The box was roughly assembled by another ES member, so the design isn't how I would do things. No problems there, it was way cheaper than what it would be if I did it myself, and was a good base to start from. It didn't come with hardware, I'm going to try running the hardware backwards to avoid the batteries. There's stick on furniture protectors keeping the batts off the aluminum, and holding them in place. All edges were filed smooth, and the screw holes for the side cover have furniture protectors below them. It's very secure, I'm happy with it. I can violently shake it and nothing moves or makes noise.

I'd like to get a new double crown front fork, but they look really expensive! Double crown would be key to limit travel and damage to the wires. The stock fork sure is sketchy. I never rode the bike yet, so I don't know how it's going to be at 50... I'm concerned about the brake destroying the fork rather than the speed itself.

I got the swing arm, and then had to run out the door. The picture you see is as far as the axle went in, which I'm very happy with. I need to drill and tap it to clamp, since I hear the threads on the axle are butter. It's probably the Powdercoat, it looks thick and smooth. I'll file it down snug. Do you think it would be wise to drill/tap in the middle of the two welded dropout plates, or just clamp with one small bolt in each?

[Farfle]

The weld will be very hard steel, use a good center punch and a really good drill bit , cause it will want to dive away from the seam. Other than that it should work great.

[ZOMGVTEK]

...The front end won't stay down.

Its way quieter than my GM, and probably around twice the torque. The bike is insanely heavy, the motor feels heavier than everything else.

[ZOMGVTEK]

I only went around the block a few times, but the few people walking appeared to be quite interested at how I was doing wheelies on my bike, silently, without pedaling. The bike looks a little rediculous, so I'm assuming they figured it out.

Is the Genisis prone to lifting the front? Anything past 1/2 throttle lifts the front end. It feels like it only takes a few kW before it seamlessly lifts. My old bike would lift rather suddenly and harshly at high power. If that one tipped back, you snap off the throttle and lean real quick. The Genisis feels very controlled when it lifts, but it does so quite easily. Could be the rider position. I need to put a few bricks on the bars or something. Don't know how much power I'm feeding it, the CA isn't connect, and shunt isn't calibrated anymore. Its probably 8kW or so, I programmed the controller for 50A, and lightly soldered the shunt for more regen.

[neptronix]

Welcome to having a crapton of torque. Dual suspension helps shoot you upwards as well. This bike is lighter than your others as well, isn't it?

Adjust your handlebars & seat as far forward as possible. Cut down your phase amp to battery amp ratio. That's how i manage to survive what the Magic Pie puts out.

[ZOMGVTEK]

The phase amps is set to 120A, 50A battery. Cells are probably around 4.0V. It could be that my 12 FET is dumping tons of power, don't know just yet. At double the power, this bike might be dangerous.

My first build was 114 lbs or so. But it was more or less even on the frame. This bike is lighter than my previous, but the motor is HEAVY. It feels like about 3 1kW Goldens with the thick slime tube and tire mounted. All the weight on this bike feels like its in the rear. I'll break a scale out in a bit and see how bad it is. It feels dumb heavy, but rides great. The heavy motor makes the power really smooth. It rides much more like a small motorcycle rather than a bike.

I just realized my bike used to have a super heavy slime tube up front. The front end on this bike is quite light without it, and will probably climb hills poorly due to always lifting. I'll get one mounted up soon and see if that helps keep the front end down.

[ZOMGVTEK]

The scale says 89.5 Lbs. It feels like the rear tire carries about 70-80% of that.

The front brake was EXTREMELY hot, and was smoking after a quick ride. Never ran into that before, but I probably did 10-20 WOT pulls within a minute. Regen might be useful.


These went away to mount the box.


As it sits. The rear shock has a ton of room around it now that the box is higher.

Farfle, how far in to the square tube do those dropouts go? I'd like to mount some pegs to the swingarm for protection.

[Farfle]

Farfle, how far in to the square tube do those dropouts go? I'd like to mount some pegs to the swingarm for protection.

They should penetrate about an inch into the actual arm. I would go as close as you can to make sure you are into the dropout material

[ZOMGVTEK]

The dropouts clamp now.

I also determined why the bike felt way faster than expected... The controller was feeding it 130A+... Whoops. Guess a 12 FET can take 12kW, at least temporarily. Now I need to get a 24 FET so I can run it at stupid power levels.

[nicobie]

130 battery amps? What did you have your phase amps set to?

[ZOMGVTEK]

I'm not absolutely sure. I think I set the battery current to 50A, and the phase amps to 100. I wanted to have about 100/200A out of the controller, but I grossly underestimated my shunt modification, and the battery current was really high... Regen current is over 30A, which might be a bit too much.

It's running around 85/200 now, but I barely used it since.

[ZOMGVTEK]

Only two MOSFET replacements later, and the controller is down to a pathetic 8-9kW with two small snubbers added.
24 FET is on the way. About 15kW is where I want it to be.

I started recording some random footage until some sketchy guy interrupted and starting pounding me with questions about the bike... So I jammed this trailer together. The bike isn't that fast right now anyways, so anything real is going to have to wait. I didn't intend on doing this, and never used this video thingamajiggie on my phone before, so the footage and edit isn't ideal.

[neptronix]

That's such a sweet rear swingarm setup...

You need a 24FET, minimum, pronto, man!!

[boppinbob]

Does someone here have a link to a vendor so I can buy a single gear freewheel like zomgvtek has in this pictrure.

[ZOMGVTEK]

http://www.ebay.com/sch/i.html?_sacat=S ... 4086&gbr=1

[ZOMGVTEK]

I have a fair bit of use on the bike now, probably over 100 miles. A beefy controller is on its way, hopefully it's fast enough at 15kW.



Me and my brother took them into work today. Probably saved a few trees or something like that.

[ZOMGVTEK]

It looks like every time someone moves my bike, they rest the phase wires against an object to hold it up. So, I put some pegs on the axle...



And I managed to get the chain on.

[ZOMGVTEK]