New build, BHT mid-drive "direct", custom frame

Discussions related to motors other than hub motors.
This includes R/C motors, botttom bracket, roller and geared drives.
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Overclocker   10 kW

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Feb 06 2019 9:01am



but i neglected to discuss how to release the pressure. you could just pierce the rubber plug w/ a hypodermic needle (which is how they charge it in the factory)

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Feb 18 2019 10:49am

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first test went well

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Re: New build, BHT mid-drive "direct", custom frame

Post by trazor » Feb 19 2019 2:16am

Overclocker wrote:
Feb 18 2019 10:49am
Image

first test went well
Congatulations! after all those years, finally, a complete LEV! :thumb:
Keep practicing and post a video!

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Feb 19 2019 8:36am

trazor wrote:
Feb 19 2019 2:16am

Congatulations! after all those years, finally, a complete LEV! :thumb:
Keep practicing and post a video!

haha thanks! this project took way too long :lol: might take another year to get it painted :lol:


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Re: New build, BHT mid-drive "direct", custom frame

Post by Ianhill » Feb 19 2019 10:59am

Nice build I'll be doing the dnm mod I'll be following from a distance.

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Re: New build, BHT mid-drive "direct", custom frame

Post by trazor » Feb 21 2019 6:32pm

Overclocker wrote:
Feb 19 2019 8:36am
trazor wrote:
Feb 19 2019 2:16am

Congatulations! after all those years, finally, a complete LEV! :thumb:
Keep practicing and post a video!

haha thanks! this project took way too long :lol: might take another year to get it painted :lol:

Looks good!. The only thing I don't like are the footrests that are common bike pedals. If you plan to ride hard you will crash sooner or later and those will bend. Motorcycle footrests with spring are the solution. I use these for my bikes https://www.amazon.com/gp/product/B01EW ... UTF8&psc=1

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Feb 21 2019 11:21pm

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haha i was looking at the same thing! but blue

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i actually don't mind bending those cheapo pedals. but they might deform the frame during a crash. so yes i'll be switching to pegs soon. will add a bolt-on mounting plate here

also the 17" rear tire seems small. there's clearance for 18" but that'll add more weight and reduce the torque...

lastly, my cheapo 42A controller is weak :lol: motor never gets more than 43 degrees C. need a stronger one ASAP. was thinking of getting a Kelly KLS6022H (variable regen capable)

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Re: New build, BHT mid-drive "direct", custom frame

Post by trazor » Feb 22 2019 12:58am

Overclocker wrote:
Feb 21 2019 11:21pm
Image

haha i was looking at the same thing! but blue

Image

i actually don't mind bending those cheapo pedals. but they might deform the frame during a crash. so yes i'll be switching to pegs soon. will add a bolt-on mounting plate here

also the 17" rear tire seems small. there's clearance for 18" but that'll add more weight and reduce the torque...

lastly, my cheapo 42A controller is weak :lol: motor never gets more than 43 degrees C. need a stronger one ASAP. was thinking of getting a Kelly KLS6022H (variable regen capable)
I'm very happy with the Kelly KBS line. Maybe I'm not right... if I remember correctly skeetab user tried a KLS controller on BHT/BigBlock and those have problems with hall sensor signals. Maybe I'm recalling this wrong, but do your research.

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Re: New build, BHT mid-drive "direct", custom frame

Post by skeetab5780 » Feb 22 2019 6:31am

The BHT runs nice on the KLS or KBS series

but the LRHDD does not run on the KLS series, had to buy a KBS controller for that bike tried every solution I saw on this forum to resolve the distorted hall signal and failed

excellent progress btw! great job on the build. My Kuberg bike didn't feel right when I had a small 17" rear wheel from the voloci on it either, it handled fine and ripped but just seemed off, went with 18" from Eastgem and seems better overall, you can always change a sprocket for ratio to be same

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Feb 23 2019 1:19am

skeetab5780 wrote:
Feb 22 2019 6:31am
The BHT runs nice on the KLS or KBS series

but the LRHDD does not run on the KLS series, had to buy a KBS controller for that bike tried every solution I saw on this forum to resolve the distorted hall signal and failed

excellent progress btw! great job on the build. My Kuberg bike didn't feel right when I had a small 17" rear wheel from the voloci on it either, it handled fine and ripped but just seemed off, went with 18" from Eastgem and seems better overall, you can always change a sprocket for ratio to be same

Image

thanks! btw i taped a temp sensor to the outside case of the motor. i'm hitting 53 deg C when bogged down in the sand...

i know you've fried quite a few motors like that denzel :lol: how far do you think can we push this little BHT? a Kelly KLS6022H is probably just right, you think?

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Re: New build, BHT mid-drive "direct", custom frame

Post by DanGT86 » Feb 23 2019 1:01pm

Are you monitoring temps inside the motor? By the time the heat soaks through to the case it could be way too late for the windings.

Great job on the bike build by the way!

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Re: New build, BHT mid-drive "direct", custom frame

Post by Sauger-Junky » Feb 23 2019 3:37pm

Nice build!

perhaps you can mode your controller shunt it is described there very good

https://endless-sphere.com/forums/viewtopic.php?t=71128

I get around 100 Amp out

https://endless-sphere.com/forums/viewt ... 28&t=96858

but i dont now waht your battery does

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Re: New build, BHT mid-drive "direct", custom frame

Post by trazor » Feb 24 2019 12:21am

DanGT86 wrote:
Feb 23 2019 1:01pm
Are you monitoring temps inside the motor? By the time the heat soaks through to the case it could be way too late for the windings.

Great job on the bike build by the way!
I agree with that. I've fixed the temperature sensor (the same as the picture, with the remote display) inside the motor, on the windings with JB weld like epoxy. These motors can raise and lower temperatures very quickly, not like you see on hubs. I don't think that the sensor on the case will have enough feedback for you to pull back if the motor is at overheat temperature.

The mod is easy, you make a hole in the rubber that is kind of gasket in the cable when entering the motor, about 3mm and pass the wire of the sensor through (you have to cut it and re-solder after)

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Feb 25 2019 12:55am

Image

Image

will do the shunt mod ASAP and also the temp probe on the windings. if power is still inadequate and there's still some thermal headroom i'll probably get the kelly controller

speaking of thermal headroom. what's the safe max temp of the windings?

BTW that's a yuyangking cheapo controller

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Re: New build, BHT mid-drive "direct", custom frame

Post by trazor » Feb 25 2019 1:49am

Overclocker wrote:
Feb 25 2019 12:55am
Image

Image

will do the shunt mod ASAP and also the temp probe on the windings. if power is still inadequate and there's still some thermal headroom i'll probably get the kelly controller

speaking of thermal headroom. what's the safe max temp of the windings?

BTW that's a yuyangking cheapo controller
My temperature meter shows "Hi" above 115 Celsius. I try to stop before that, not more than 100 C, but is easy to pass that, a matter of seconds. The Denzel kit D4500 comes with a temperature sensor and a Kelly controller with a cut off of 120C. I think that is the maximum temperature common windings/enamel/magnets can take safely.

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Mar 01 2019 9:48pm



i should not have procrastinated w/ the sensor install. i would've seen that the yellow phase wire was rubbing against the rotor. eventually the insulation and copper wire wore off and started acting like brushes, hence the scorch marks

quality on this BHT motor is really crap :lol:

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Re: New build, BHT mid-drive "direct", custom frame

Post by trazor » Mar 03 2019 1:39am

Overclocker wrote:
Mar 01 2019 9:48pm


i should not have procrastinated w/ the sensor install. i would've seen that the yellow phase wire was rubbing against the rotor. eventually the insulation and copper wire wore off and started acting like brushes, hence the scorch marks

quality on this BHT motor is really crap :lol:
Bummer :(
The BHT motors are being sold again (after a long time of unavailability). https://www.ebay.com/itm/BLDC-MID-MOTOR ... 2649924278

For the price I think the Denzel 4500 has more copper, but will require other mount design.
The next time open the motor and take a view and install the temp sensor asap. On my LR BB and D4500 nothing was out of place, but you can feel how these aren't quality checked to high standards.

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Mar 04 2019 9:56am

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so i just got the temp sensor installed. bonded to the windings w/ DIY thermal adhesive. i just mixed zinc oxide powder and hi-temp silicone gasket maker

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Re: New build, BHT mid-drive "direct", custom frame

Post by Bonneville » Mar 12 2019 8:44am

Superb build. I am motivated now. Love your swing arm. Consider it stolen. Soon you please find it on my build :D

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Mar 18 2019 12:13am

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Image

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Re: New build, BHT mid-drive "direct", custom frame

Post by madin88 » Mar 18 2019 8:35am

Did you paint the frame or is it powdercoat? Looks nice :thumb:

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Mar 19 2019 6:00am

madin88 wrote:
Mar 18 2019 8:35am
Did you paint the frame or is it powdercoat? Looks nice :thumb:
rattle can :lol:

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Re: New build, BHT mid-drive "direct", custom frame

Post by skeetab5780 » Mar 19 2019 10:43am

Overclocker wrote:
Mar 19 2019 6:00am
madin88 wrote:
Mar 18 2019 8:35am
Did you paint the frame or is it powdercoat? Looks nice :thumb:
rattle can :lol:
Looks really good!

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Mar 25 2019 2:28am

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still need to tidy up the wiring. then add yellow and red graphics to the battery box to match the color scheme of the fork. etc

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then i found this lightweight 17" rim. so together w/ 12-gauge spokes should reduce weight as well as be a better match for the flange thickness of my hub (btw the sur-ron uses 12g spokes). unfortunately the rim drilled for 10g spokes so i'll have to use conical washers

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Re: New build, BHT mid-drive "direct", custom frame

Post by Overclocker » Mar 29 2019 12:40am

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