this is my first thread in ES, and after enjoying a lot some of the great builds here, I decided to post mine, hopefully it can be of help for someone and I can get some extra advises in the journey...
First, I needed to define what I wanted when I started to think about this project, here some points:
- I wanted an e-bike plenty of power and not spending a fortune, that is why I selected the cyclone kit, 4kW motor and BT controller.
- The power setup includes 18s lipo pack (10000mAh) which should be capable of 4.3kW peak (with the supplied 60A controller). I could, eventually, parallel two packs to double the range).
- Pedelec + Throttle (moto style), so PAS implemented.
- No big money on the donor, that would need to be heavily modified.
- Decent suspensions and brakes to handle the power. So proper shock and fork and hydraulic brakes are a must.
- I should try to handle from the beginning the twisting torque of the motor to assure a stable and straight motor chain-line, which will save a lot of problems later when handling that many watts.
- "Monocoque" frame to put everything inside and protected (battery pack, cables, connectors), and to assure very high stiffness.
The first task was to find a donor frame. It is actually plenty of possibilities out there, and I did not need a lot of time till I found the donor. A New Old Stock Alpinestars RSA840 frame. It was a very cheap option (@ 40€) even if it did not include the shock in the price, I already had a Cane Creek DB Air shock collecting dust. I also bought a cheap second hand Rock Shox Totem fork (good stiff 40mm stanchions spring fork). Whit the Cyclone kit at home I could start working...
I did not take any pics of the frame before chopping it, but it was like this one:
"La Catalogne, enfin, peut se passer de l'univers entier, et ses voisins ne peuvent se passer d'elle". Voltaire.