E-bike Xm

Show off your E-bike creation here.
xmasta   10 W

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Location: Tallinn, Estonia

E-bike Xm

Post by xmasta » Jul 04 2011 1:04pm

Hya, thought I share my build here too :)

I initially had electric scooter, Image but it was pretty much useless most of the time because of where i live, Estonia, its next to Finland so, muchos bad weather and snow etc.

After being to work with bicycle everyday for two winters (insert video later) i decided that the scooter is just stupid and i should get my bicycle motorized.

So the scooter got sold and e-bikekit motor/controller + Ping 48v10ah ordered.
I couldnt use the bike i was driving with cos of the funny frame Image that had no place to put the batteries the way i would like so went for the old one:
Image
Then there was some long wait, making batteries out of old pizza boxes to plan placing them etc.
Image

Finally the stuff was all arrived and it was time to put it all together, also I decided to try my hand at fiberglass, i was not too good at it :P



and so i got myself going, but i was not happy by the looks and so on.
Image

Then i started designing new battery box that i could insulate from cold and weather, but also take off the bike when neccessery without too much hassle.

Voila, batterypack V2 was a go: Image

After it was halfway done, a friend showd up who had some bike lying around waiting to be thrown out but offered it to me. And well, it was much lighter and only needed little paintjob and crankset, also rear cassette was dead but i didnt need it anyway.

The new bike had much bigger frame that actually made my "removable" option a lot easier to solve.
Image bottom slides to a plate i've put into drinking cup holder and rear piece goes around seat tube, behind there i'll put a lock on it.

So this is where i'm at now, got myself new controller from Lyen and prepping the new box for near future system transfer :)

Image

the original thread on local zero emission vehicles forum: http://zev.ee/foorum/viewtopic.php?f=11&t=177 - i bet it's funny through google translate.
Last edited by xmasta on Jul 06 2011 6:32pm, edited 1 time in total.
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

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Whiplash   100 MW

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Re: E-bike Xm

Post by Whiplash » Jul 05 2011 9:02am

NIce build! I like the box!
Power is a fascinating thing, the more you have, the more you want, but the real power is having the restraint not to use it all at once...............Um...Yeah..

The harder you work.....The luckier you get!!

"People who say it can't be done are often interrupted by those that have already figured out how to do it!"

Email me @ currentcycles@gmail.com
OR check out http://www.CurrentCycles.net

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Jul 05 2011 10:46am

Thanks :)

Added some metal bracing to the fiberglass box, the ride is really pumpy so I want to make it a little more sturdy.

Image

Now i must figure out what will i use to insulate the batteries, then there's connections to be made..

Also crafted anderson plate holders, so i can put both power out and charge ports on the rear side and do not need to open the box for anything.

Image

here's the photoshopped design that i measured and printed to cut mine out, if anyone wants to print/cut some for himself too
Image
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

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beast775   100 kW

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Re: E-bike Xm

Post by beast775 » Jul 05 2011 11:44am

great build,the battery in the frame is the best.much better than a heavy slow scooter :) .
2 FINGER SALUTE TO ESSO.no buying gasoline for 14 years now.
I spent all my money on bicycles women and beer the rest i just wasted.

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Jul 08 2011 9:38am

metal works today!

this will shield my main power switching relay and host a good surface for keyswitches that drive main power and controller power.

Image
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Jul 14 2011 10:03am

Installed motor on my new bike and tested out the Lyen controller but it makes disturbingly loud noise and doesnt spin up to speed that the old controller does.

There must be some configuration mixup, like hall sensors pulsing the phases wrong or something.. sent Lyen an email but not sure how busy he is, maybe someone here knows those settings and stuff and can also help with it?

it's a 12 x 4110 MOSFET Extreme Modder Controller LYEN Edition controller, and i'm using the e-bikekit.com read DD motor, the first controller on the video is also from that kit, e-bikekit.com 20 amp thingy.

.video removed.

here's the screenshot from settings i'm on atm:
Image

different phasedegree? Halp
Last edited by xmasta on Jul 15 2011 5:30am, edited 1 time in total.
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

torker   1 MW

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Re: E-bike Xm

Post by torker » Jul 14 2011 12:45pm

It seems on Lyen controllers 2 colors on the phase wires have to be swapped. Not sure of the colors but a search here should bring it up. Second version of the bike looks good. Welcome to ES
Dave When I die I want to slide in sideways yelling WooHoo what a ride !

Giant Rincon w rear 9C 6*10 36 v x 20 amps
Specialized FSR Comp 9C 6*10 48v x 30 amps

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Jul 14 2011 2:06pm

torker wrote:It seems on Lyen controllers 2 colors on the phase wires have to be swapped. Not sure of the colors but a search here should bring it up. Second version of the bike looks good. Welcome to ES
Hello and thank you for the kind words.

Phase wires were off before connecting and i noticed it, blue green red didnt match i had to switch side ones, then i ran this test and thought about well, maybe original setup was correct just wrong colors.
tried how they were initially but that mixed it up even worse and motor didnt move at all.
Should i try third alignment? and .. what should it be then.. :D
on the video they run: yellow green blue
non moving was: blue green yellow
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Jul 14 2011 2:15pm

i did try now
yellow blue green
green yellow blue

also doesnt move, only the original matching colors moves, so, phasedegree?
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

torker   1 MW

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Re: E-bike Xm

Post by torker » Jul 14 2011 2:56pm

Sorry I never programmed one. I run Ebikekit controllers with a modded shunt. I just added wire to the shunt to up the amps and I run 60v through them. Poor mans setup :oops: Someone who knows programming will help soon I hope.
Dave When I die I want to slide in sideways yelling WooHoo what a ride !

Giant Rincon w rear 9C 6*10 36 v x 20 amps
Specialized FSR Comp 9C 6*10 48v x 30 amps

xmasta   10 W

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Re: E-bike Xm

Post by xmasta » Jul 15 2011 5:29am

ok it was not configuration problem, it was still phase wires + hall wires, initial mixed up phases lyen sent were correct, he didnt mix up hall wires so that was what i had to do, after he resent me the controller manual :)
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Jul 16 2011 10:52am

Image

for them extra long sessions of angry birds!

but really, for gps and video recording :P
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

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etard   1 MW

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Re: E-bike Xm

Post by etard » Jul 16 2011 11:23am

Love the Battery box and especially the charging port! Also, the bent metal piece looks great.
Four wheels moves the body, Two wheels moves the soul
Thanks to Justin @ http://www.ebike.ca He brings the soul to ES

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Jul 18 2011 4:28pm

etard wrote:Also, the bent metal piece looks great.
Thanks, "the bent metal piece" got my attention next, it is shielding relay and battery connections and hosts keyswitches for main power, controller and precharge :)

Image

still much to do with them wires, must shorten many that run to the handlebar and see how I can hide the rest of them after getting mudguards installed.
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Sep 20 2012 2:32pm

Forgot to update my stuff here, so some highlight of what has happened with this project in the meantime.

when all got assembled it looked like this:

Image

that was august, 2011
Attachments
ebike-xm-v2-03x.jpg
v2 complete
ebike-xm-v2-03x.jpg (221.02 KiB) Viewed 1173 times
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Sep 20 2012 2:45pm

April 11, 2012, a crazy woman managed to run me over, when i was exiting from traincrossing, managed to avoid the worse and hit her parallel on the side but somehow the car still managed to pull the bikes frontwheel under its fronwheel and slammed on the ground i was. Probably cos of the angel i was at when trying to dodge the car by pulling hard to the right.
killakolla1t.JPG
killakolla1t.JPG (45.18 KiB) Viewed 6021 times
new front wheel, new rear rim.. the crash pulled some of the spokes through the rim.

.. started thinking about new frame.. no suspension whit our shitty roads is painful.
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Sep 20 2012 2:50pm

July 2012, bought alu frame and front suspension, it is 1.8kg and looks nice. Started working on the new battery pack required for new frame size
Photo 18.07.12 17 53.51x.jpg
project blubike
Photo 18.07.12 17 53.51x.jpg (75.22 KiB) Viewed 6021 times
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Sep 20 2012 2:59pm

scrapped the idea for now and going to sell this frame.. has 5 year guarantee so shouldnt be problem to find a buyer, drove it only for 200m :D

Reason, did not want to do another big build and still end up without full suspension.. i cant drive on anything but car roads cos of the road conditions off of it. And it's not so great on the main roads either at times.

Looked around for affordable full suspension frame but downhill frames are totally out in my country.. I cant believe how lucky guys in US are, wallmart 150$ full suspension bike.. argh. Anything close to acceptable obtainable here was ~$1000, out of my budget range.

so.. I went and looked up my old FS frame.. of the "coca-cola" bike.. and decided i'm going to modify it :)
coca-ftw01.jpg
custom frame plans
going to weld new pipes to the red zones, bring the suspension connection little lower and cut out everything in the green area, for battery space.
The pipes over rear suspension are going to go like this ( )
what do you think? ;)
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

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Whiplash   100 MW

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Re: E-bike Xm

Post by Whiplash » Sep 21 2012 8:12am

Sounds like a good plan! Make sure you update the build as it goes!
Power is a fascinating thing, the more you have, the more you want, but the real power is having the restraint not to use it all at once...............Um...Yeah..

The harder you work.....The luckier you get!!

"People who say it can't be done are often interrupted by those that have already figured out how to do it!"

Email me @ currentcycles@gmail.com
OR check out http://www.CurrentCycles.net

xmasta   10 W

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Joined: Apr 04 2011 2:38am
Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Jan 27 2013 11:41am

well, there's been lots of work to do and not enough time for my new ebike frame/build. Plans have changed quite bit and hopefully soon i can continue working on it.

Here are some pictures to hint whats coming.
Photo1 02.11.12 20 08.51.jpg
new frame box
Photo2 17.11.12 2 45.42.jpg
rear indicator+brake+light
Photo3 04.12.12 17 57.05.jpg
front daylights
Photo4 19.01.13 9 21.32.jpg
rgb adressable
Photo4 19.01.13 9 21.32.jpg (210.48 KiB) Viewed 1507 times
Photo5 23.01.13 16 21.59 2.jpg
programming and testing indicators, brakes
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Feb 15 2013 10:01pm

ebike-xm-T1 - moving forward
image00151.jpg
ebike-xm-T1 making of
image00151.jpg (53.71 KiB) Viewed 5933 times
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

torker   1 MW

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Re: E-bike Xm

Post by torker » Feb 16 2013 9:02am

Sorry to hear about your accident. Looks like you are busy getting a new ride ready to go. Old desktop pc as a sawhorse :)
Dave When I die I want to slide in sideways yelling WooHoo what a ride !

Giant Rincon w rear 9C 6*10 36 v x 20 amps
Specialized FSR Comp 9C 6*10 48v x 30 amps

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Mar 08 2013 11:22am

Cos of the breaking spokes (after crash respoking was done poorly with weak spokes) I had to order new proper spokes from ebikekit and thus take everything apart, used the time to clean up the motor aswell..
Photo 02.03.13 10 19.07.jpg
after 5000+ km
Photo 02.03.13 10 18.57.jpg
whoopsie, rust!
Bought some proper grease and oil now .. :P

Also paint has gotten very loose on the engine.. have to repaint that.

PS. I wonder if taking the motor apart to grease inner bearings AND closing it securely would be an easy thing to do.. I unscrewed bolts from one side for painting and seemed like they were superclued too.. or something hard like that
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

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lbz5mc12   10 kW

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Re: E-bike Xm

Post by lbz5mc12 » Mar 10 2013 7:40am

I just installed the rear DD motor from e-bikekit on my GT Aggressor hard tail. I'm currently using a 36V 20Ah battery from bmsbattery.com. I also have a 48V 10Ah on the way from them. I have a 2 battery switch on the bike and will be using both batteries, 36V for street and 48V for dirt. I like your mid mount battery installation which is something I'm trying to figure out for my bike. I was thinking of bolting a rectangular piece of sheet metal to the water bottle carrier mounts and using industrial strength velcro to attach the batteries to it. The battery packs are the wrapped shrink tube style. Velcro the batteries together, one on top of the other, velcro the controller on top of the batteries and then velcro everything to the plate. Then maybe wrap some duct tape around everything just to be safe but leave the controller exposed for cooling. I just have to figure out what to use for side panels. It's a 22" frame so I have a lot of room to work with.

xmasta   10 W

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Location: Tallinn, Estonia

Re: E-bike Xm

Post by xmasta » Mar 18 2013 5:49am

Had to order new spokes cos of the poorly made respoking i got from local dealer(6 spokes broken til i ordered new ones), and made it myself!
Also while at it, scraped off paint that had come loose on the motor and repainted it.
Photo 08.03.13 18 11.07.jpg
pre-painting
Photo 17.03.13 17 50.05.jpg
painted and re-spoked
My build: 9C rear DD + Greentime 15fet + 60v Lipo (4s1p x12 hardcase hobbyking)(now on second set) (RIP)
New built at "xm-blue" (Q100H "kit" test from bmsbattery.com)

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