stewrobb
1 W
10KW 2WD Winter build
Just uploaded pictures from my phone, so not the best quality, but they shall do for now.
Electrical:
20s 15Ah Turnigy 20C Hardcase pack
2 x 18 fet 4110 controllers, stock at 60A for now, but capable of much more
2 x 1000w China hubs (front and rear both with 35mm stators)
- 11awg phase to windings on front hub (done), 10awg phase on rear hub (to be done)
- vented hubs (to be done)
Bike:
120mm Spinner aluminium forks
Ironhorse Boundary Hardtail aluminium MTB (originally with 2 hydro discs, but the front doesn't fit, guess it's calipers for me)
DoctorBass Torque arms for rear hub (on the way)
Ebikes.ca Torque arms and C washers for front hub (need $)
So I'm getting started on this Build, have most of the parts, just need some components for the final assembly, and need to do a little work on the rear hub. I realize I may have to replace the front forks with steels ones at some point, but for now, this is what I've got, and I'd hate to lose 120mm of travel for some shitty steel 80mm cheapo forks. Love to hear what people have to say about it though.
Unfortunately my package containing my 2 x 18 fet's, 2 motors, and spokes for my 26 inch rims was mangled by the customs officials, everything was taken out of the packing and just taped together. When I got it from UPS, over half the 72 spokes were bent (checked and counted, hoping to have enough for one wheel), and had been banging the motors, removing paint on the outside perimeters and chipping some of the covers. No biggie there, I can deal, but the spokes really pissed me off. The controllers were fine other than bent brackets. My front motor wouldn't spin at all, which really cheesed me, upon further inspection, I found a 1/8w resister, yes a resister stuck to the magnets, wedging the stator. WTF is a resister doing in there, they don't even use resistors for building motors lol. Either way I was going to open it, so it turned out alright, although because I tried to force the motor (thinking a bearing was stuck or something), I left a mark on the lams, so possible short and loss of some power, it was hard to tell, it could be fine.
So far, I have run the front hub ~11 guage wire, and sealed the hub with silicone for use in the winter (in the spring/summer I will vent the hubs). I've got the bike down to the frame just begging to have motors put on it. I think I may just buy aftermarket spokes, the stock ones seemed pretty flimsy, although they are being replaced by my supplier. The hubs have the old style hollow axle, welded to the stator.
I've got to get down to the local electronics store and get some lower strand 10 guage, I used super high strand audio power wire for the ~11 guage front hub (stripped wire and heatshrinked it), and it was quite the awful ordeal, I won't be doing that again.
Should have all the parts in the next two weeks, I'm dying to get it together. I'll post some pictures in the next while. Cheers,
Stew
UPDATE
While I was waiting for the spokes, I decided to get started on modifying my motors. I started by running 5 x 18ga insulated copper per phase (tried 7, then 6, all to no avail), think that is about 11ga. Forgot the temp sensor on the rear, but that definitely wasn't happening after I pulled and soldered those phase wires. Then I drilled both the side covers near the bearing, and around the circumference.
I ran my front motor with about 12ga, using thin stranded wire, but I definitely prefer the thicker wire, much easier to deal with. I drilled this as well.
A couple of days ago, before I got the spokes, I was cleaning my place, and unfortunately I moved the flimsy shelf the motor was on(as pictured) without thinking. Ended up having my motor fall 4 feet onto a tile floor, braced with cement. frocking brutal, although I think it may be my instinctual subconcious method of self preservation, telling me not to put a motor at 4 or 5kw on a aluminium front fork lol. My 2WD plan is not dead, just delayed. For a future build with a much stronger suspension fork. I also just got a 500W 320rpm/48v geared motor (without freewheel) in 26 inch rim, nice except a couple of bent spokes, and a rim that I don't think can be trued lol. Got a lot on my plate, but I will get back to it for sure.
Finally received the spokes from the manufacturer to build my wheel, and they sent me the wrong size, 5mm too long, so I wasn't able to use my nice double walled rim, although I tried . Ended up putting it on a crappy (but true) rim from a cheap Canadian Tire bike I had modified as a gas bike (but got tired of it...and the cops). I was very happy with my first wheel building experience, I think I did quite a good job, though possibly too tight. Wasn't as hard as I thought it would be. True test will be when it's spinning with me on it .
- Installed Doc's torque arms, and am just waiting for the epoxy to set
- Set up a 12v Lighting system with rear brake light and dual LED beams (not very bright though, gotta upgrade that)
- Mounted and wired everything
To Do: (for the morning)
- Build battery (already have harnesses)
- Install rear battery box (Marine Dry Box)
- Set up rear disc
- install chain
- reinforce torque arms
- Destructive Testing
I gave it a test with my old pack at 20s (3.84 per cell) while I picked up the back wheel, and that thing bloody flew, the knobby tires moved an obscene amount of air. I bought the packs to upgrade to 24s, but I think it would be silly. Definitely leaving it at 20s at least for the first couple weeks, although those lipos are burning a hole in my shelf just sitting there :?.
Will post pictures soon. Cheers,
Stew
Just uploaded pictures from my phone, so not the best quality, but they shall do for now.
Electrical:
20s 15Ah Turnigy 20C Hardcase pack
2 x 18 fet 4110 controllers, stock at 60A for now, but capable of much more
2 x 1000w China hubs (front and rear both with 35mm stators)
- 11awg phase to windings on front hub (done), 10awg phase on rear hub (to be done)
- vented hubs (to be done)
Bike:
120mm Spinner aluminium forks
Ironhorse Boundary Hardtail aluminium MTB (originally with 2 hydro discs, but the front doesn't fit, guess it's calipers for me)
DoctorBass Torque arms for rear hub (on the way)
Ebikes.ca Torque arms and C washers for front hub (need $)
So I'm getting started on this Build, have most of the parts, just need some components for the final assembly, and need to do a little work on the rear hub. I realize I may have to replace the front forks with steels ones at some point, but for now, this is what I've got, and I'd hate to lose 120mm of travel for some shitty steel 80mm cheapo forks. Love to hear what people have to say about it though.
Unfortunately my package containing my 2 x 18 fet's, 2 motors, and spokes for my 26 inch rims was mangled by the customs officials, everything was taken out of the packing and just taped together. When I got it from UPS, over half the 72 spokes were bent (checked and counted, hoping to have enough for one wheel), and had been banging the motors, removing paint on the outside perimeters and chipping some of the covers. No biggie there, I can deal, but the spokes really pissed me off. The controllers were fine other than bent brackets. My front motor wouldn't spin at all, which really cheesed me, upon further inspection, I found a 1/8w resister, yes a resister stuck to the magnets, wedging the stator. WTF is a resister doing in there, they don't even use resistors for building motors lol. Either way I was going to open it, so it turned out alright, although because I tried to force the motor (thinking a bearing was stuck or something), I left a mark on the lams, so possible short and loss of some power, it was hard to tell, it could be fine.
So far, I have run the front hub ~11 guage wire, and sealed the hub with silicone for use in the winter (in the spring/summer I will vent the hubs). I've got the bike down to the frame just begging to have motors put on it. I think I may just buy aftermarket spokes, the stock ones seemed pretty flimsy, although they are being replaced by my supplier. The hubs have the old style hollow axle, welded to the stator.
I've got to get down to the local electronics store and get some lower strand 10 guage, I used super high strand audio power wire for the ~11 guage front hub (stripped wire and heatshrinked it), and it was quite the awful ordeal, I won't be doing that again.
Should have all the parts in the next two weeks, I'm dying to get it together. I'll post some pictures in the next while. Cheers,
Stew
UPDATE
While I was waiting for the spokes, I decided to get started on modifying my motors. I started by running 5 x 18ga insulated copper per phase (tried 7, then 6, all to no avail), think that is about 11ga. Forgot the temp sensor on the rear, but that definitely wasn't happening after I pulled and soldered those phase wires. Then I drilled both the side covers near the bearing, and around the circumference.
I ran my front motor with about 12ga, using thin stranded wire, but I definitely prefer the thicker wire, much easier to deal with. I drilled this as well.
A couple of days ago, before I got the spokes, I was cleaning my place, and unfortunately I moved the flimsy shelf the motor was on(as pictured) without thinking. Ended up having my motor fall 4 feet onto a tile floor, braced with cement. frocking brutal, although I think it may be my instinctual subconcious method of self preservation, telling me not to put a motor at 4 or 5kw on a aluminium front fork lol. My 2WD plan is not dead, just delayed. For a future build with a much stronger suspension fork. I also just got a 500W 320rpm/48v geared motor (without freewheel) in 26 inch rim, nice except a couple of bent spokes, and a rim that I don't think can be trued lol. Got a lot on my plate, but I will get back to it for sure.
Finally received the spokes from the manufacturer to build my wheel, and they sent me the wrong size, 5mm too long, so I wasn't able to use my nice double walled rim, although I tried . Ended up putting it on a crappy (but true) rim from a cheap Canadian Tire bike I had modified as a gas bike (but got tired of it...and the cops). I was very happy with my first wheel building experience, I think I did quite a good job, though possibly too tight. Wasn't as hard as I thought it would be. True test will be when it's spinning with me on it .
- Installed Doc's torque arms, and am just waiting for the epoxy to set
- Set up a 12v Lighting system with rear brake light and dual LED beams (not very bright though, gotta upgrade that)
- Mounted and wired everything
To Do: (for the morning)
- Build battery (already have harnesses)
- Install rear battery box (Marine Dry Box)
- Set up rear disc
- install chain
- reinforce torque arms
- Destructive Testing
I gave it a test with my old pack at 20s (3.84 per cell) while I picked up the back wheel, and that thing bloody flew, the knobby tires moved an obscene amount of air. I bought the packs to upgrade to 24s, but I think it would be silly. Definitely leaving it at 20s at least for the first couple weeks, although those lipos are burning a hole in my shelf just sitting there :?.
Will post pictures soon. Cheers,
Stew