Fizzit's RC freeride build log - now with videos

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Apr 21, 2012 12:59 am

I made a light!

Just in time for the sun to start being up when I leave home in the morning and when I go home in the evening :P
Oh well, it'll become useful in 6 months or so.

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The LED's I used are three Cree XMLAWT LED's. I am running them at 3000ma each and they are rated at 1000 lumens each at this current. Then for the reflector I used this:
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In the box is one of the little Synqor 48v-5v DC-DC converters. It feeds the LED's about 27W and draws about 30W so it does not get warm at all. I have a potentiometer to trim the output voltage. As you can see, the box and light are not complete (not waterproofed) but they have survived a couple of rainy rides already :mrgreen:

Here's some beamshots. I locked the exposure on my camera so they would be as good as possible for comparison.

old headlight (spiderfire 700 lumen flashlight)
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Prius headlights
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Bike light
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The bike is next to the car so the car casts a shadow in the right side of this photo.

As you can see the bike light is aimed pretty far down so I don't irritate the people in the metal boxes more than I already do! Also I think it's pointing slightly to the left...
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by amberwolf » Apr 21, 2012 2:50 am

Nice and bright light! Buuuut...

If you notice how the Prius lights don't light up above the fence to the side, but the bike light does so very brightly? That's going to potentially blind people, or at least make it harder for them to see anything but the glare of the light. It's a really common problem with lights not made specifically to conform to headlight standards (even with aftermarket HID lights on cars!).

I know that I myself can't see past such lights on a truck, for instance, and have almost run over a pair of pedestrians because the lights were so bright I could not see the road or anythign else other than the lights of the truck (not even the truck itself) on an otherwise very poorly lit road. The pedestrians were not wearing light clothing and were crossing the street on one of it's darkest sections, with nothing lit up behnd them to let me see them, but my own headlight would have lit them up sufficiently if it weren't for the blinding truck lights in the opposing traffic lane. I only saw them at the last second and was able to swerve around them. (they weren't watching for traffic either, or they would have seen me and hopefully been rushing to get out of my way when I didn't slow down for them, not knowing they were there).

So, it could be important to mask off the beam before the optics so that it doesn't shine up high like that.

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Apr 21, 2012 3:58 pm

I am indeed aware of this problem and working to rectify it. Thanks for your concern!
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Apr 23, 2012 11:11 pm

My town is a mess, there is road construction everywhere this month. Today, I misread a traffic cop's hand signaling and got to ride on a nice freshly paved road that had no other cars on it :mrgreen:

I was wondering why all the other cars were turning left, because there was clearly a lane straight ahead. As I went past him he yelled something along the lines of "GET OFF THE ROAD" but it was too late by then :lol:

Why do I never have my camera on when interesting things like this happen :cry:

Anyways in other news I made an ass-ugly chain guard for the motor chain. I was hoping that it would make it quieter but it seems to have gotten worse. I will keep it simply because it keeps the chain clean. Pictures will be posted once I recover from my shame
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » May 09, 2012 7:12 pm

Well here's some terrible cell phone pictures of my new chain guard and the brown gunk that has collected on the inside in the last 50 miles or so of riding. I am not sure if that much dirt has managed to get inside the chain guard, if it is the dirt that was previously in the chain, or if it is some kind of finely ground rust/lube sauce.
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Also here is a video from last week where everyone stops for ducks to cross the road. It was pretty cute. Then I also added a video from today where in the process of blowing a stop sign (a very slow-walking old person was about to use the crosswalk and I had to get there first) I saw a dude riding a very strange looking motorcycle with a small child in a sidecar. They both stared at me, probably because I was being a bit of an asshole by riding through the stop sign and because I was riding a vehicle that is almost as strange as theirs.



In other news, I have learned to ride with no hands.
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » May 31, 2012 8:26 pm

Image
http://i.imgur.com/dGOQ2.jpg

It's like christmas! I finally got my new fork seals and an excessive amount of fork oil. After 1500 miles (and however many more were put on by the old user) I think it deserves a rebuild.
I also got one of the fancy new ACS crossfire freewheels from Motomel that are machined for eBike usage. I am really excited to put it on and I feel that it will be much better than my old sickbikeparts freewheel, with less rumbling and sprocket wobbling.

Also I am planning on building a unified battery box/controller box/other stuff box that will straddle the top tube. I will hopefully save money on building it by using the .040" aluminum panels that are left over from building our electric car's battery boxes. Here is a picture of what I think I will make it look like on the inside (color coded for what aluminum goes where):

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http://i.imgur.com/pqDFu.jpg

Today I rode in probably the worst rain I have ever ridden in and it was not fun but I survived. Summer is a little late around here
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Jun 02, 2012 10:55 pm

Well, in a burst of hyper-productivity coupled with a complete lack of a social life this weekend, I managed to rebuild my fork last night and swapped my freewheel for the fancy new ACS one today.

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The fork, taken apart

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The replacement seals for the fork

Rebuilding a fork for the first time was not too hard, and I haven't ridden the bike yet but just pushing it up and down it feels a lot less sticky.

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In the process of replacing my freewheel, I discovered that my bottom bracket is unthreading itself on the right side... which makes sense because it is reverse threaded so it unthreads in the direction that you pedal. Who designed this???
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by bzhwindtalker » Jun 03, 2012 2:14 am

Actually the botto bracket is made to work this way, and under normal pedaling loads it screws itself up. Maybe too little pedaling modifies the way it should work^^

haha I love your replacement seals ;)
Image

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Jun 07, 2012 11:49 pm

But... If you're looking from the right, you pedal clockwise and it unscrews clockwise?? Maybe this is one of those things I'll never understand :mrgreen:

I'd just like to say that MotoMel's ACS freewheel is working great and has much less slop and is much stronger than my old Dicta. Anyone running a mid-drive should get one of these freewheels.

Today I let my friend use my bike in first gear in my alley. Of course I didn't bring out my camera :roll:
He had ridden my RC motor electric scooter before and I warned him that the throttle was sensitive, but somehow he still did a wheelie and fell of backwards right away :P
Luckily my bike didn't hit the ground. I'll see if I can get him to do it again and I'll take a video this time...
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Jun 17, 2012 2:24 am

One year since I hit that car that turned in front of me! No crashes since. Feels good. Although I still don't remember most of that day, I guess that part of my memory will never come back. Ah well, I'm sure it was traumatic and embarrassing anyways.

Also I bought more LiPo from the USA warehouse and started working on the new battery box. 888wh here we come!!!

So I got a full time job in a new building for the company that I worked at last summer. I just mapped it out and it looks like is a 15.2 mile ride. I have to get on I90 (a freeway with a bike path on it) and cross the lake, then cross Mercer Island, then cross the lake again but I still might be able to do it in less time than to take transit. Driving would be faster but the electric car isn't done yet. I might get to bike commute to work this summer :mrgreen: it'll be interesting if I'm riding 32 miles a day and mingling with the lycras on the bike path. Helmet cam videos will be more interesting for sure
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Jul 07, 2012 11:59 pm

I made my new battery box to fit 44v 20ah! It also holds my controller and stuff. Here are some bad pictures that I just took.
It's not a pretty box but I think it should be a heck of a lot better than what I had.

old
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new
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original plan
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what resulted
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And it's made of .032" 6061 T6 aluminum sheet cut with a band saw, bent with a vise, slathered with silicone, and riveted together. I ended up not needing the structural cross-braces. The side panels are held on by rivnuts and are sealed (hopefully) with window/door sticky stuff. It's not sealed well now because it's summer, but hopefully I can get it rain-proof soon! Right now there are just wire grommets to keep them from chafing on the rough panels.

The box will be tested in two days, I will ride it to my work 16 miles away, charge it, and ride it back. If all goes well :lol:

I was going to test it friday but I discovered that I had a bent .5" steel jackshaft from a chain-derailing event in which I forgot to tighten the nuts on one of the freewheel sprockets and it fell off :cry:
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Jul 08, 2012 8:17 pm

Here's my bike charging for the 16 mile trip tomorrow!

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And here's the new Mountain Mirrycle I got. I think it will come in handy.
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On another note I switched to a 12t #35 sprocket when I made my new jackshaft. The bike is noticeably quieter! This should keep some people from getting mad if I ride past on the bike path. Hopefully.
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Jul 09, 2012 11:25 pm

I survived my 34 mile ride today!!! It turned out to be a little longer than expected, the ride to work took 2 hours because of some 'technical difficulties' and getting lost. The way back was only 1 hour but I still got lost :P

The ride started off well. However, 4 times in bellevue, the set screws on my jackshaft bearings came out of the jackshaft and the chain derailed :roll:

I finally got them tight enough with a pair of plyers and set on to I90. It was a beautiful trip there! Here are some pictures that I captured from the long-ass video of the trip that I don't think anyone in their right mind would watch :lol:

My mirror helped a huge amount, it made riding a lot easier. I regret going for so long without one.
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In the morning I made my entrance to the warehouse in style, riding straight up the ramp outside, through the cargo doors, into a room in which there was apparently a meeting going on :mrgreen: oops! they had never seen me riding before so they were probably a little baffled.
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In the afternoon I got a little lost, less lost than before but the trip home still took over an hour :roll:
I started it off leaving the warehouse and I had to mix it up with traffic in downtown Seattle
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Then I headed through some nice parks that lead to the seattle end of the I90 bridge trail.
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Slightly ominous entrance to the I90 tunnel
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Then onto the I90 bridge!
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It was a great view except for this guy halfway across who was either completely and utterly baffled by my bike or was giving my the evilest eye that he could muster. I'm gonna go with the bafflement. Other than him, no one really seemed to care about my bike as I went slow and pretended to pedal when I passed people.
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Then through bellevue
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and into my hometown kirkland, where I was unfortunately snarled by traffic for a few minutes before I found a detour to my house.
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And that concludes my 34 mile commute!
I put in 15ah when I got to work and I haven't charged the battery yet. I'm unsure whether I used more or less capacity on the way back, but I'm pretty pleased overall with how it performed. And I'm happy to say that my new battery box didn't break!
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by amberwolf » Jul 09, 2012 11:59 pm

A mirror helps so very much that it is baffling to me when people I know refuse to use one for whatever reason. :?


BTW--the blacked out sections in the warehouse pic have me intensely curious what is so secret it must be covered up. ;) I have been resisting the temptation to try to figure it out from shadows and such.... :lol: If I had time, i might try anyway, but I don't.

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Jul 10, 2012 10:46 am

amberwolf wrote:A mirror helps so very much that it is baffling to me when people I know refuse to use one for whatever reason. :?
It's true! I used to live in constant fear of someone passing me. Now I feel like I have eyes in the back of my head. It definitely changes the whole riding experience.
amberwolf wrote:BTW--the blacked out sections in the warehouse pic have me intensely curious what is so secret it must be covered up. ;) I have been resisting the temptation to try to figure it out from shadows and such.... :lol: If I had time, i might try anyway, but I don't.
Hmm... well looking at the video, I'm not even sure what it is :P
It's stuff for a project at work that I'm not a part of, so I don't know if they have any secrecy/privacy concerns and I just want to stay on the safe side.
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Jul 18, 2012 9:34 pm

This monday, I rode to work again. On the trail I wore a bike helmet, and I realized that my bike is pretty loud and wears on your ears after a while. My experiences on the trail got me considering a switch to a belt drive for stage 1 of the reduction.

I'm not sure about this decision as there have been some people that have switched from belt to chain, and they had to have a reason for that. I think that if I get'r done right I could have a reliable belt setup that is free of the noise, grease, and wear of a 8000rpm #25 chain.

For the reduction, I'm thinking about having a 15t motor sprocket and a 72t larger sprocket. 5mm pitch x 15mm wide HTD belt. This will be comparable to my 13-70 current reduction. As recumpence has kindly advised me, I will need a tensioner to make sure the sprocket has enough wrap, because belt teeth are a lot weaker than chain.

This should be interesting, if anything. Thoughts?
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Aug 09, 2012 3:08 pm

Belt drive: implemented

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I rode the 17 miles to work today and it was quiet and that was the only difference I noticed from the chain drive 8)
I thought I was going to have to take off the motor mounting plate to drill a hole for the tensioner but I discovered that I could use one of the motor mounting bolts to hold it. And it slides with the motor.

I also made a parallel board with a bunch of HobbyKing JST-XH extension wires so all my cells are paralleled and there is quite a rat's nest in the battery box. Oh well!
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Thanks to recumpence for the tips on the belt drive!
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by Ratking » Aug 14, 2012 12:17 pm

Nice work, looks sharp with the belt drive. How much battery do you carry on the bike?
Do you know how many wh\km you use?

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Aug 14, 2012 11:48 pm

Ratking wrote:Nice work, looks sharp with the belt drive. How much battery do you carry on the bike?
Do you know how many wh\km you use?
Thanks! I've got 12S at 20AH now. I think I use about 27 wh/km on average. It ranges from 24 to 31 depending on how fast I'm riding.
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Aug 24, 2012 5:42 pm

My friend decided this year to build an electric bike for his senior project as long as I would help him. He has a little experience with electronics (he knows + and -, and what volts and amps are) and none with bikes, so I helped him figure out what batteries to use, how he wants to drive the bike, and what components to purchase. For his bike, he had the idea to write to Raleigh and ask for a free bike... two weeks later and he texts me with this picture:

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I haven't seen it but it looks pretty nice. I am pretty jealous. Perhaps I should have waited a while to build my bike so I could get a free one too :lol:

I'm going to help him do a simple mid-drive setup because he originally wanted to build an RC bike like mine, but I convinced him to do a mid-drive instead.
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by bzhwindtalker » Aug 25, 2012 9:31 am

With this kind of triangle space it should be easy to put the motor and the batterys within the frame !

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Sep 09, 2012 7:10 pm

Funnily enough, my friend has decided to mount the motor outside of the frame :? He says it will make it so he doesn't have to have an idler sprocket or have a chain "shroud". I'm not sure why he'd need those things but it is his bike so he can do what he wants! :lol:

On friday I was riding back from playing some tennis and going about 35mph up the hill of death (it's not a very steep hill but my bike has suffered multiple failures going up it :roll: ) when I decided to shift down a gear so I could rev the motor a little higher. Something didn't like that and my back wheel locked up and I fishtailed for about 100ft and made a long skid mark going off the road. It's funny because I had just been thinking about how long my bike had gone without a significant failure.

When I got off the bike I found that my derailleur hanger had snapped in half and the derailleur was now located in the spokes of my wheel, with the chain wrapped between the spokes and the cassette, and going through the destroyed derailleur and then around the cranks. I am not sure why this happened. There should be no load on the rear derailleur. Maybe my chain was very stretched and it slipped? I hadn't looked at it in a while, just lubed it occasionaly. Luckily my derailleur hanger is removable and is compatible with the common kona "h" hanger so my frame is still usable. My derailleur was pretty worn out and this may have had something to do with it, it is always possible that the chain locked up in the derailleur and tore it off. I shall purchase a new derailleur, konda derailleur hanger, and chain, and attempt to replace the two spokes in my back wheel with care, because that is my nice wheel (the front one sucks).

Also I have noticed that my battery pack is going a little out of balance. I paralleled all the cells but when it's charged, there's still about .05v difference between the highest and lowest - like highest is 4.17 and lowest is 4.12. My father has a large number of Cellog-8s for the electric car and I've been looking at the cells with one of them, they are very handy.

I think I will get one of these
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or one of these
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to take care of my balancing woes once my bike is in mechanical working order.
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Oct 02, 2012 1:05 pm

I fixed my bike! A new derailleur, front chain sprocket, chain, and derailleur hanger got it back in working order. For one day, yesterday. Then today I was riding to work and the brand new chain fell off of the brand new front sprocket and got all bent up when I shifted gears. Luckily, I now have a car for backup! Except this weekend, it started leaking a ton of oil because I apparently did something wrong when I replaced the oil pan gasket. So my bike and car are out of comission due to my failed repair attempts. And I gave my transit pass to my sister. And I gave my road bike to my friend. I guess I will walk to school for a couple of days. But for the bike, I think I just need a chain guide for the front sprocket to keep the chain from derailing when I shift gears in the rear. I don't understand why it does this but hopefully it's fixed with a guide for the chain.
Last edited by fizzit on Oct 02, 2012 3:34 pm, edited 1 time in total.
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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Re: Fizzit's RC freeride build log - now with videos

Post by amberwolf » Oct 02, 2012 3:08 pm

If the chain isn't within a narrow range of angle when it enters across the top of the front chainring, it'll derail, because the edge of the chain begins to catch on teh teeth..

Just having a front derailer on there and locked to the position over the chainring will stop this--it is what I had to do to CrazyBike2 when I still had a rear shifter and multiple speeds on it, for the same reason.

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Re: Fizzit's RC freeride build log - now with videos

Post by fizzit » Oct 02, 2012 3:36 pm

That's a fantastic idea, should keep me from having to buy or even make anything :) thanks!
-Colin
my first ebike, a freeride mountain bike, using a turnigy 80-85, castle hv160, and turnigy lipo:
https://endless-sphere.com/forums/viewto ... 80#p607020

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