Custom Giant Dh, Lightning Rods Big Block, Nuvinci N171

Joined
Mar 1, 2013
Messages
301
Location
sheffield u.k
So after many months reading everything i could on this great site i decided i needed to build another e bike.
Bike 1 is a Trek remedy with an AFT kit which has not missed a beat.
However the quest for more power has truly bit me so here goes.
I managed to buy 2 Giant DH frames for 80 gbp which is the bargain of the century, one has been posted to Aus. to Sam D for chopping and welding and the other is a reference point so i can mount stuff and get an idea of what is going to be where.
As the Giant is a Dh frame the geometry is not the best for road riding so it will be stretched by 68mm at the wheels and 3.5 degrees taken from steerer angle to lessen the chopper feel and make it so you do not have to book a corner in advance in writing.

List of bike bits i have now
Chris King headset
Chris King front hub
Hope v2 brakes and 203mm rotors
Nuvinci N171 hub
Marzocchi Monster T forks 200mm version
Sun 24" double wide rims
Renthal Fat bars or clip ons as i have some that fit.
24" by 3" Berm Master tyres or 20" by 3" mc tyres

Electrical bits list
Lightning Rods Big Block with chain primary and temp sensor
24 fet lyen controller
3 speed switch
throttle
C.A. v3
6 6s 16ah Multistars to run at 18s
 

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Whoa! A build thread!

What sort of moron carves up that kind of quality frame and plays with the geometry? :wink:
 
hahaa i found this an was buzzing thinking there was more of us but its you...lol;]
man this is gonna be sweet ..
nice to see it on the frame ..some quality veg on display too;]
 
slightly less rough photoshop of frame design.
It may be tweaked a bit from here.
 

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Can't fault you for messing with the geometry since I'm doing it too right now. Looks like you have a solid plan though. Is your welder a surgeon? Mine sure has been. I think yours will be tougher though I'm only modifying the swing arm. I should have it back in the next couple days and I'll post some more pics. Keep moving forward Cheek I'm excited to see how it works out.
 
Obiwan007 said:
Can't fault you for messing with the geometry since I'm doing it too right now. Looks like you have a solid plan though. Is your welder a surgeon? Mine sure has been. I think yours will be tougher though I'm only modifying the swing arm. I should have it back in the next couple days and I'll post some more pics. Keep moving forward Cheek I'm excited to see how it works out.

After reading many build threads with DH comp frames i knew the steering needed sorting and wheelbase extending too.
If you cut the down tube and crossbar and add a 75mm piece in the down tube you get 68mm wheelbase increase and 3.5 degrees of steepening at the steerer.
The welder seems confident in his skills and has done several e bike before, though none as complex as this.
Also after staring at the photoshop pic i did not like the top tube at the seat area so i tweaked it a little.
 

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Bike 1 is a Trek remedy with an AFT kit which has not missed a beat
Would it have been cheaper and easier then starting again going to the Big block since you already have a 48v AFT/cyclone kit to use the same 48v battery and cyclone type kit and double its power by using forced air cooling and gear hardening mods to make it handle 3kw continuous and 5kw peak ?
http://endless-sphere.com/forums/viewtopic.php?f=28&t=68648
heck I don't even know if the big block can handle 3kw continuous as it has no forced air cooling ? I bet it would have been a lot more compact and less weight then the BB as well.
Also the noise would be quite similar as you have chain on the primary side of the big block which will be quite noisy.
 
Megsy73 said:
Bike 1 is a Trek remedy with an AFT kit which has not missed a beat
Would it have been cheaper and easier then starting again going to the Big block since you already have a 48v AFT/cyclone kit to use the same 48v battery and cyclone type kit and double its power by using forced air cooling and gear hardening mods to make it handle 3kw continuous and 5kw peak ?
http://endless-sphere.com/forums/viewtopic.php?f=28&t=68648
heck I don't even know if the big block can handle 3kw continuous as it has no forced air cooling ? I bet it would have been a lot more compact and less weight then the BB as well.
Also the noise would be quite similar as you have chain on the primary side of the big block which will be quite noisy.[/quote

I just fancied more power and a new mistress, very interesting read with the forced air cooling.
It would not be suitable for U.K. use as its always shit weather here.
I went with the chain primary as A the belt is untested at the power levels i want to try and B you cannot fully enclose the belts as they get warm and stretch.By the time i have made a chain cover it should be a little quieter than my AFT although the noise really helps with people.
PLus it is much more fun starting again with all my newfound knowledge courtesy of this fine website.
 
Final photoshop pic of frame after tweaking it a bit.
I am happy with the shape now.
Please ignore random colours it will be black.
Darren
 

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--freeride-- said:
The Battery Box is going to be stronger than the Frame and the Motor Mounts :)

LOL It needs to be as it will have the motor bolted through it .
I did not want to twist the frame with the Big Block Motor.
 
Some more pics would be great.
How much phaseamps do you plan?
My small block for example does well with 75 phaseamps.
I Heard that the big block is double the coppermass of a smally, do you think it will handle 150 phaseamps?

Which max speed have you calculated with the nuvinci?
 
sascha2770 said:
Some more pics would be great.
How much phaseamps do you plan?
My small block for example does well with 75 phaseamps.
I Heard that the big block is double the coppermass of a smally, do you think it will handle 150 phaseamps?

Which max speed have you calculated with the nuvinci?

I have no idea of phase amps as i will not be programming my controller and do not know how.
I will try running at 18s and 60a first to see if the hub will take the power then up to 80+ if it will.
I am more of a grinder , welder and hammer type of bloke.
Max speed with a 48t front and a 16t rear works out to 48mph.

What would you like pics of as all i have is a pile of bits as my frame is in Australia and i am in the U.K.
Darren
 
--freeride-- said:
The Battery Box is going to be stronger than the Frame and the Motor Mounts :)
Team Australia reporting in ;)
Strong = good.
 
Choice of handlebars for bike,
Renthal fat bars or clip ons with the handles extended as the originals in pic are a bit short.
 

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Are you tempted to go silver forks and chassis at all fella? I know you said to coat if black for you...
 
Just got first pic back after powder coating, frame should be posted back to the U.K. soon for the build to start.
 

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