My Ebike with OLDSCHOOL aesthetics Buildthread

carl2.0 · Nov 12, 2011

I just wanted to introduce the E S community to my new electric project I code named “PIWI” . Its suppose to be similar performance to the electric motorcycle I did http://endless-sphere.com/forums/viewtopic.php?f=10&t=28479 but on a bicycle platform.

Im lookin to use :
A Generic Ebay electric bike kit 48v 1000W (GM motor or so it looks) from Yescomusa or a similar vendor.
840 Whr packFour 15 Ah batteries
Oldschool cruiser bike as the donor frame
26” triple tree fork
Front and rear disc brakes
Fiberglass battery housing
*Upgrades
- Hoping to have a chat with Lyen to get a controller that would give me something like 55- 60 kph out of my GM motor… Im assume Ill need something like a 48v 60A controller w/ a CA cable
- Cycle analyst

I spent quite a bit of time researching different motorcycle styles and designs, yet again I found myself attracted to the vintage. For this design would have to say my muse came from the board track and café racers. Since I was using a cruiser frame I wanted to create a design which maintain the aethestetic of the bike in a simple functional manner (no faux shit).
Let me kno what you think !

View attachment 3

The 3D renders
I produced trhese models using Solidworks, Im not nearly a SW pro.. they gave us a couple classes last yr n Ive been fiddlin around with it ever since. This was as close to the idea in my head I was able to 'digitize' but I like them so far

The build should get on its way soon, Build pics soon to come !

dogman dan · Nov 13, 2011

I'm sure you are planning to add disk mounts for brakes? That's a coaster brake bike so no brakes once you put a rear motor on. At least the front disk will be easy. Don't think that bolting calipers to the frame is going to work good enough. You'll find the rear dropouts the wrong width too, but that's easy to fix.

nonlineartom · Nov 13, 2011

I'm just starting a similar build myself. I plan to change the front forks to ones that support disc brakes and to use a universal adaptor on the rear. There are various units to add disc brake functionality to a non disk brake frame, take some tweaking and grinding but they work. I'll be keeping my eye on this thread

carl2.0 · Nov 13, 2011

Ive already ordered the front disc brakes so thats a sure shot. Im lookin into gettin the Conhis motor dic brake kit http://www.conhismotor.com/ProductShow.asp?id=72 for the rear... not sure if they will work straight out the box tho :S

geetarboy · Nov 13, 2011

That's a sleek looking design Carl, but it may be pretty light in front with the saddle so far back and a rear hub motor.

nonlineartom · Nov 13, 2011

I've got the conhismotor rear disk brake kit, it's difficult. You've got to have a threaded side cover on your hub motor that supports adding a disk, if you dont have that threaded side cover you are totally out of luck. The brake adaptor fits onto the axle in place of the spacer tube. I couldnt find a disk brake calliper that would fit with enough clarance, Avids and Tekros were all too thick and interfered with the hub itself, it can be fixed by spacing the rotor out further but it's a faff.

carl2.0 · Nov 13, 2011

geetarboy said:
That's a sleek looking design Carl, but it may be pretty light in front with the saddle so far back and a rear hub motor.

I was worried about the 52 lb the 17 ah batteries would add to the bike, even more concerned when I realised with the styling I did Id only be able to mount them far in the front, but now u mention that with the seat to far back it would be light up front I guess it may be a good ting.... Not sure how much that 52 lb would negate my weight n the motor torque tho :S

something Ill have to think about

Samd · Nov 13, 2011

Looks a little like the orphiro motorbike out of the netherlands. Different price tag i will wager...

http://www.orphiro.nl/

carl2.0 · Nov 14, 2011

:O ur right it does, I like their styling tho... maybe I can borrow a few design queues from them. Its very sleek n the renders are great

Ill be going hub tho.... a MARS on a bicycle seems like an over kill right now.

Hillhater · Nov 14, 2011

carl2.0 said:
I was worried about the 52 lb the 17 ah batteries would add to the bike,
something Ill have to think about

so you were planning on using Lead ?
I would think about something else !
for example ..
4 of the 6s lipo packs would weigh 8lbs and give better performance & range. ..& $200 !

liveforphysics · Nov 14, 2011

Lead = fail.

Toorbough ULL-Zeveigh · Nov 14, 2011

NiMH FTW!

Samd · Nov 14, 2011

(Makes face like Samuel L Jackson and yells "Why you no LiPo?")

carl2.0 · Nov 14, 2011

Currently SLAs are the cheapest option over 10 Ah. Also getting RC lipos mean I have to import which will take longer

carl2.0 · Nov 14, 2011

Until my stuff gets here Ill be force to sit n dream so this id how I figured Id arrange the innards.
The batteries on trays which are fixed to mounting which Ill weld (get welded) to the frame and the controller mounted on the saddle tube.. or thats what I think its called

View attachment 1

Hillhater · Nov 14, 2011

carl2.0 said:
Currently SLAs are the cheapest option over 10 Ah. Also getting RC lipos mean I have to import which will take longer

how long before you actually need the batteries ( finished build ?)
What cost for 4 x 17Ahr SLA ?
you do realise that 17 Ahr of SLA is in practice only equivalent to 10 Ahr of RC lipo !
The lipo will outlast the SLA's

I doubt there is $100 difference in cost.

Hobbit · Nov 14, 2011

Dude! you've just posted two photos of a naked piwi. I dont know if you have Aussie style slang terms where you are but over here......that's awesome! :lol: :lol:

carl2.0 · Nov 15, 2011

Im currently in the Caribbean and SLAs at 17AH are a rip off honestly( around $100 US each) but to ask for RC Lipos is begging to get laughed at... its too niche an item to find locally n Importation duties on the Lipos is sure to add ATLEAST $50 on their price... not to mention the 2 weeks of waiting 2. Ill def consider getting them after Ive built the bike

PS
Lol I have No Idea what a naked piwi is in aussi :S

carl2.0 · Nov 15, 2011

:S peer pressure. Such interest in RC Lipos l found myself on HobbyKing and I found this guy

http://www.hobbyking.com/hobbyking/store/__8582__ZIPPY_Flightmax_5000mAh_6S1P_20C_.html

Now I have 3 questions

- Is this a good deal for a 6S 5ah ?
- Is there any special wiring for these in series/parallel/charging ? ( yes Im an RC/Lipo noob)
- How well will a 48V kit run at 44.4V particularly wrt to low voltage cutoff ?

Also what are thoughts on using B grades for E bikes ? ...bad idea ?

http://www.hobbyking.com/hobbyking/store/__15496__B_Grade_5000mAh_6S_25C_Lipoly_Battery.html

ohzee · Nov 15, 2011

I have 12 of those zippies and I LOVE them to death. I had SLA at first and it's night and day between the two.

The B grade stuff is not worth buying as it just wont last. Maybe to run some lights , but not to power a ebike.

I love the look of your build cant wait to see the real thing. keep up the good work and go lipo

AussieJester · Nov 15, 2011

As others have said forget the lead

KiM

carl2.0 · Nov 15, 2011

The chargers for these things seem quite eccentric tho, looks like it will be a lil project on its own to devise the means of charging and monitoring these batteries SAFETY inside the frame

Hillhater · Nov 15, 2011

carl2.0 said:
Im currently in the Caribbean and SLAs at 17AH are a rip off honestly( around $100 US each) but to ask for RC Lipos is begging to get laughed at... its too niche an item to find locally n Importation duties on the Lipos is sure to add ATLEAST $50 on their price... not to mention the 2 weeks of waiting ...

Holy Cr**p man ! ... Lipo is going to save you money !!
Yes, those Zippy's will work fine for you, and remember that when charged those packs will be at 24-25v each ( 48-50v for your system), and will likely never go below 42v even under load when near empty. I be you don't know how much the SLA's voltage sags when in use ??
charging need not be a problem, what would you have used to charge the SLA's ?
read some of the lipo charger threads on here for guidance, and be diligent if this is your first lipo.
something like this could be suitable..
http://www.bmsbattery.com/alloy-shell/25-alloy-shell-240w-lifepo4li-ionlead-acid-battery-ebike-charger.html

carl2.0 · Nov 15, 2011

For the motorcycle I used a smart charger from batteryspace... very simple job, just disconnect the controller connect the charger and wait for it to charge, thats what Im use to right now so I guess I will have to do some reading on the Lipos...

http://www.batteryspace.com/leadaci...6ah-60ah110vonlystandardfemaletamiyaplug.aspx

Been readin some of Ypedals adventures with lipos on his site, what Lipo threads would be recommeded for rookies ?

wrt to battery sag... Ive been riding blind... holding out for the cycle analyst with the Lyen controller

Hillhater · Nov 15, 2011

carl2.0 said:
what Lipo threads would be recommeded for rookies ?

A good starting point . http://endless-sphere.com/forums/viewtopic.php?f=14&t=26621

carl2.0 said:
..wrt to battery sag... Ive been riding blind... holding out for the cycle analyst with the Lyen controller

CA is the ultimate, but for value & useful info, the HK WattMeter takes some beating @ $25 ..

http://www.hobbyking.com/hobbyking/store/__10080__Turnigy_130A_Watt_Meter_and_Power_Analyzer.html

My Ebike with OLDSCHOOL aesthetics Buildthread

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