Endless Sphere

Great news! I'm glad it has worked out.
That's a fairly narrow voltage range for zero to full throttle, but as long as it is stable and repeatable you should be able to work with it.
Hope it rides great and can handle a bit more power than originally without overheating too much!
Dave

Hi Mike, Re the throttle behavior on the BBS02.. it seems lots of people are having similar issues, especially on motors with recent controller firmware, and several people are working on solutions. Check out the thread called "Throttle Behavior" on ES, E-Bike Non-hub Motor Drives. Other t...

Relating to this problem, but using programming rather than external electronics: I found this in PacoMarkE ' s well documented thread about his BBS02 commuter bike build: "Throttle. The throttle was acting like an on/off switch instead of a graduated response. I read up a little and changed se...

I am not an expert in this, but I know that some strain gauges and Hall sensors output voltages between 1 & 4 volts through their range, and this matches Hall effect throttles, so it is at least possible that the torque sensor output is already usable, at least for a controller where you can sel...

Ok, seems like a dead end for that particular system using throttle. That's a shame. Did you get any feel for the power the motor / controller combination could produce without overheating etc? Any chance of picking up the torque sensor output and using that as a "throttle" signal into the...

Hi Casainho, watching with interest! FWIW: Looks like someone else is offering updated firmware: https://www.youtube.com/watch?v=tj2aYtma64o Obviously a "how to load the firmware" instruction video for people who have bought his disc. Not very informative, but may be of interest. I couldn'...

Hi Mechhead, Sounds an interesting project! I had often wondered about using different controllers on the "packaged" mid-drives, so I will be keen to see what results you have. Are you planning to run it throttle-only, or are you going to try and use the torque sensor signal? I would expec...

Hi JRH, Re your idea: "I've been considering how to implement a mode of throttle that would limit speed near 30mph on flat, but still let it rev out on downhills and not bog down going uphills. Seems that an inclinometer would be the magic component to meet the law's criteria on flat ground whi...

@casainho, The idea of being able to teach the controller new tricks is really interesting, and could allow users to tune the system to suit their riding style and conditions.. a real bonus. As far as the inclimometer is concerned, just remember that acceleration and braking will be read as a change...

Jbalat, Thank you very much for the strip-down videos you have made on the TSDZ2 motor unit.
Not difficult, but it helps so much to know in advance what you will find, what tools are needed, and the sequence of work.
Much appreciated.
Dave

Find this thread here on Endless Sphere: https://endless-sphere.com/forums/viewtopic.php?f=28&t=83450 A BBSHD matched with a "Phaserunner" Sinewave controller. Looks as though it might do what you are hoping for. Regardless of what motor you choose, it should run quieter using a Sinewa...

One of the main reasons the manufacturers of e-bikes offer underpowered systems is the legislation in the various countries where they are manufactured and sold, that restricts the maximum power allowed. The manufacturers have to offer bikes that are legal, so not all the blame lies with them. Part ...

Hi Mike, Yes, most of us have done a project like that.. I picked up a Rockshox Monarch air shock at 165mm eye-to-eye to upgrade my daughter's mountainbike a while ago, and it is a great little shock. We found another, either 150 or 155mm for a friend's Mongoose mountainbike also, so the shorter sho...

Hi Try-all, I really like the look of your project.. should be awesome to ride once you get it finished. One comment though: your battery box blocks all direct airflow to the motor, and even the mounting plates enclose the motor to the sides, so there will not be much airflow around the motor. It mi...

Hi Wgtnpete, Looks like that chainring is high quality, but have no experience with it myself. Narrow-wide chainrings do actually seem to keep the chain on the chainring well, and look after the chain better also. Since I swapped to a narrow-wide on my mountainbike I have not had the chain drop off ...

Another possibility is mechanical friction, either inside the motor unit or external. I read somewhere that another user of the TSDZ2 found that the inside of the crank arms rubbed on the side of the motor casing. He removed the crank arms, ground a couple of mm of metal off the inside face and re-i...

Hi Skeet, If there is continuity between battery negative and hall sensor negative, that is good.. connect the negative of the 9V battery to either the battery negative or the hall negative, and the +9V of the battery to the hall sensor supply Positive. (You will have to disconnect the hall sensor +...

Hi Roadstar, I don't have personal experience with that particular motor, but I have noticed with other brushed motors in the past that sometimes the brushes make a noise when the commutator is turned in one direction but not the other. Is the motor that makes the noise new or used? Hard to judge wi...

Several people have put a second drive chain on the left side of the bike, driving from the motor to a sprocket mounted to the 6 bolt holes for the disc brake. Obviously the sprocket has to be on a flange that moves it inward slightly, and the disc ends up moving outwards slightly, so it would depen...

"I would be curious to know if the 148mm x 12mm boost spacing and axles are part of the reason to deal with side force? I only ask because I noticed a significant difference in stiffness when I went to a 140mm x 12mm rear frame on my Ellsworth Epiphany." Hi DDFred, I guess as tyres get wid...

When designing the rear suspension, keep the bearings for the main swing arm as wide apart as possible, to reduce the maximum force on them and keep the back end as stiff as possible. Three reasons: -The chain forces on e-bikes are greater than normal bikes, and there are reports of frames bending s...

Hi Fred,
Could you please copy the website address for the G521 kit and post it? I can't find any webpage showing the unit or kit for sale..

Thanks
Dave

Looking at the Bafang website, they offer a mounting bracket for the m500 & m600 motors: http://www.bafang-e.com/en/components/component/accessoires/fp-g520.html This looks like the part that surrounds / mounts the motor and forms the bottom of the frame on the blue bike shown a few posts ago. I...

"What other models have you read about that get good reviews?" Several of the bikes I have read about get good overall reviews, but the one that seems to get the best comments ("Climbs well, descends well, great fun to ride, no weaknesses, has agility and stability" type of comme...

Geometry: The Torbo Levo gets good reviews for its handling, but there are others that get better, so here's my take on the geometry. Head tube angle: between 66 & 67 degrees Seat tube angle: 75 degrees Chainstay length (Bottom Bracket to rear axle): 440mm or as close as you can get to that figu...