Reconfigure my e-bike. Advice/feedback needed [pics].

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pwd   100 W

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Joined: Oct 11 2011 12:01pm
Location: Ontario, Canada

Reconfigure my e-bike. Advice/feedback needed [pics].

Post by pwd » Jan 27 2013 12:03pm

Hi everyone, I have some things that I would like to correct/reconfigure on my bike. Plans are to:

Fix front disk brake and prevent it from warping (when the front brake is engaged, I can see the disc bend to a certain angle.)

Fix the sloppiness in my rear suspension (there is play in the rear pivot point on the shock absorber) What is this piece called?

Re-arrange my batteries so that they are in the triangle of the frame and can still be removed when bulk charging. They are currently stored in a .50 cal ammo can and strapped to the rear rack.

Here is what I'm dealing with:
Image

Please have a look at the rest of the photos to see what I'm dealing with:

Album: http://imgur.com/a/trMKH
Last edited by pwd on Feb 17 2014 8:56pm, edited 2 times in total.
Current Build:
Rocky Mountain Element
Magic Pie 4 front + Leafmotor 1500 rear w/ WCEC 18fet
em3ev 14S5P 30Q + 14S6P 25R pack

Old Build:
GIANT ATX 980 w/ Cycle Analyst v2.25
Golden Motor Magic Pie (internal controller) X2
14S3P 15aH: 6X 6S 5000mAh + 3X 2S 5000mAh LiPo packs
My thread: http://endless-sphere.com/forums/viewto ... 5&p=693208

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geeeyejo1   1 kW

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Re: Reconfigure my e-bike. Advice/feedback needed [pics].

Post by geeeyejo1 » Jan 27 2013 12:45pm

Woohoo - All Wheel Drive! Looks good. Although the triangle looks a bit tight, at least you are working with LIPO and the bricks can certainly be configured easier than a LIFEPO4 pack...
1997 Gary Fisher HooKooEKoo Hard Tail MTB, 48V 1000W Yescom Rear Kit, 48V 15 AH Lifepo4 Sunthing28 Pack

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pwd   100 W

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Joined: Oct 11 2011 12:01pm
Location: Ontario, Canada

Re: Reconfigure my e-bike. Advice/feedback needed [pics].

Post by pwd » Jan 29 2013 8:17pm

Mods, would this be better in the General E-Bike section?
Current Build:
Rocky Mountain Element
Magic Pie 4 front + Leafmotor 1500 rear w/ WCEC 18fet
em3ev 14S5P 30Q + 14S6P 25R pack

Old Build:
GIANT ATX 980 w/ Cycle Analyst v2.25
Golden Motor Magic Pie (internal controller) X2
14S3P 15aH: 6X 6S 5000mAh + 3X 2S 5000mAh LiPo packs
My thread: http://endless-sphere.com/forums/viewto ... 5&p=693208

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dogman dan   100 GW

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Location: Las Cruces New Mexico USA

Re: Reconfigure my e-bike. Advice/feedback needed [pics].

Post by dogman dan » Jan 30 2013 7:17am

There should be an adjustment on the disk caliper that will allow the stationary side of the pad to be adjusted to align with the disk better. On my cheap stuff, it's a allen socket in a largish threaded aluminum disk on the caliper. You might have to remove the hub weel to acess it with a wrench.

Or shims might help under the disk itself.

The play in the rear suspension linkage is another matter. It's possible you might need to replace frame parts, hopefully the wear is not on the frame or swing arm itself, and you can just get new bushings or something easier.

If you can't fit all the batteries in the frame, at least get as much weight as you can off that rear rack. So you just have a few packs back there, in a much lighter box.

Two helpings of pie, bet it can do some nice hills easy.

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pwd   100 W

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Joined: Oct 11 2011 12:01pm
Location: Ontario, Canada

Re: Reconfigure my e-bike. Advice/feedback needed [pics].

Post by pwd » Feb 02 2013 9:40am

Hey dogman / geeeyejo1, the disc definitely has adjustments on each side of the caliper... which I have tried to adjust the best of my ability; problem is its like the disk or wheel has a bit of a camber going on compared to the caliper. What could that be?

As far as the rear suspension, the play is in the top most pivot point of the swing-arm, but I can't tell if its the arm itself or the bushing(is that what its called)?

My goal is to move all the batteries to inside the frame, and have some sort of enclosure. I'd like to make a decent quality metal enclosure but not sure it would be too heavy. I was thinking of having something about the same thickness as the ammunition container I'm currently using.

Dual pies are a real blast! Lots of acceleration power. Random question though.... I have the amperage adjusted to full on both of them (30 amp cont. each and 50 amp peak each) but I've only ever seen it draw a maximum of about 1450 Watts (via my Cycle Analyst). I expected to see at least 2000W when going up hills or from a hard acceleration. Batter pack fully charged (14S) give me 58 V. Is this normal behavior?

I've had my bike parked for winter, but I'd like to get it all fixed up and ready for spring. Occasionally the front motor cuts out, which can be frustrating when you need the power; so I am also gonna crack the pie open and see if there are any obvious issues with the wiring.
Current Build:
Rocky Mountain Element
Magic Pie 4 front + Leafmotor 1500 rear w/ WCEC 18fet
em3ev 14S5P 30Q + 14S6P 25R pack

Old Build:
GIANT ATX 980 w/ Cycle Analyst v2.25
Golden Motor Magic Pie (internal controller) X2
14S3P 15aH: 6X 6S 5000mAh + 3X 2S 5000mAh LiPo packs
My thread: http://endless-sphere.com/forums/viewto ... 5&p=693208

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dogman dan   100 GW

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Joined: May 17 2008 12:53pm
Location: Las Cruces New Mexico USA

Re: Reconfigure my e-bike. Advice/feedback needed [pics].

Post by dogman dan » Feb 02 2013 9:57am

My assumption on that camber is that the axles are not seated right into the dropouts. Doe the rim look crooked, or just the disk. Maybe just crap machining on the disk mount part of the cover? Bent caliper mount on the frame?

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pwd   100 W

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Joined: Oct 11 2011 12:01pm
Location: Ontario, Canada

Re: Reconfigure my e-bike. Advice/feedback needed [pics].

Post by pwd » Mar 12 2013 3:46pm

Minor update to my build: I plan on installing the original Rockshox Judy C fork that came with the bike (I didn't realize it had a disk brake mount).

One thing I really don't like is how off center my wheel is... if only they made a wider suspension for for a 14MM axel. (Does anyone know if such a thing exists?) :?:

This time I'm going to pay close attention to how many times I file away the dropouts; to ensure both sides have been adjusted as evenly as possible. I've been told the Rockshox fork (even though lower end model) should be better than the RST I'm using now. Just did a dry fit with the front Pie, its going to be tighter than the RST; which may require some additional filing. I will add some pics later.
Current Build:
Rocky Mountain Element
Magic Pie 4 front + Leafmotor 1500 rear w/ WCEC 18fet
em3ev 14S5P 30Q + 14S6P 25R pack

Old Build:
GIANT ATX 980 w/ Cycle Analyst v2.25
Golden Motor Magic Pie (internal controller) X2
14S3P 15aH: 6X 6S 5000mAh + 3X 2S 5000mAh LiPo packs
My thread: http://endless-sphere.com/forums/viewto ... 5&p=693208

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23skidoo   10 W

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Location: San Francisco

Re: Reconfigure my e-bike. Advice/feedback needed [pics].

Post by 23skidoo » Mar 12 2013 5:38pm

Try your ammo can with a 4-5' extension cord. Put it in any backpack and try riding.

It's simple, improves handling and security, and helps you move the battery to charge.
26" folder full suspension with crystalyte 3525 and rc lipo in a Kevlar box in a backpack. Wife bike bmc lyen. Honda elite scooter conversion with Crystalyte 5404

e-beach   100 MW

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Re: Reconfigure my e-bike. Advice/feedback needed [pics].

Post by e-beach » Mar 12 2013 6:39pm

I am going from a wooden battery box frame to all aluminum. It will take a while to finish, and will be much heaver they my wooden frame, and way more expensive but I will be much happier with it when done. A metal box is a bit of a commitment compared to wood. Others have done theirs out of wood and fiberglass and they have turned out nicely. Be sure to consider all medium of container material because something other then metal might work better for you.
Attachments
final battery box assembly ver 2feb13 exploaded view.JPG
Favorite Quote: "This is L.A., sugar. There is no 'over the top." --- Chris Erskine

Current build: Liahona w/ cheap front suspension and suspension seat post. Yescomusa 36v 800w generic front hub motor. 15ah Headway triangle mounted pack. Tronsung 30 amp,

Previous Build:1992 Trek Antelope 800 - Bone Crusher (no suspension) - Yescomusa 800 watt 36 volt front wheel kit. Don't do it! Get suspension!!!

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