Second Build Trek Fuel EX 5.5

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Second Build Trek Fuel EX 5.5

Postby sflorlando » Fri Dec 30, 2011 5:45 pm

Hello All,

Love the Forum. For xmas I bought myself a 2008 Trek Fuel ex 5.5

This time Im trying to do it right by getting a better quality bike with a proper size triangle.
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Fri Dec 30, 2011 5:49 pm

Here are the specs.


Frameset... 17.5
Frame...Alpha Red Aluminum w/R1 Trail Tuned Suspension, Hi/Lo chainstays, oversized sealed bearings, 120mm rear wheel travel

Front Suspension...RockShox Tora 289 U-Turn w/travel, rebound, 85-130mm
Rear Shock...Fox Float R w/rebound, custom tuned
Wheels...Shimano M475 disc hubs; Bontrager Ranger rims
Tires...Bontrager Jones XR, 26x2.2/2.25"; 27 tpi
Shifters..SRAM X-5, 9 speed
Front Derailleur...Shimano Deore
Rear Derailleur...SRAM X-7
Crank...Shimano M442 Octalink 44/32/22
Cassette...SRAM PG950 11-34, 9 speed
Pedals...Alloy platform w/clips and straps
Handlebars...Bontrager Crowbar Sport, 25mm rise
Stem...Bontrager Sport, 10 degree
Headset...Aheadset w/semi-cartridge bearings, sealed
Brakeset...Avid BB-5, mechanical disc w/alloy levers; 185mm rotors (160 mm rear rotor on 15.5, 17.5, 18.5" sizes)
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Fri Dec 30, 2011 6:06 pm

I took a quick ride around the block and noticed how much lighter, smoother it was. The walmart bike I had was a beast, suspension sucked and took up the entire frame. Enough pedaling, time to dismantle it.

I took off the wheel and removed the rusty chain (will need to replace). Here is the picture of the dropouts.

IMG_20111230_171523.jpg
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Fri Dec 30, 2011 6:10 pm

I will be removing my hs3540 motor and placing it on this bike. Batteries will consist of 66v 20 ah lipo pack in a Falcon EV frame. Any thoughts on which Torque arms I should use. I have used some of Doctor Bass's torque arms and although they seem extremely durable, it sort of messed with the rear derailer. Of course I may have implemented incorrectly but was looking for alternatives. Any thoughts?
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Re: Second Build Trek Fuel EX 5.5

Postby Pure » Sat Dec 31, 2011 12:41 pm

Sounds like the makings of a great build. I think that bike should serve you well.
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Re: Second Build Trek Fuel EX 5.5

Postby Drunkskunk » Sat Dec 31, 2011 12:58 pm

Looks like a fun ride. should be a great build.

you could always cut the dropout hanger off the Doctorbass torque arm
Buy the ticket, take the ride.
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Sat Dec 31, 2011 5:09 pm

Thanks guys. So far the build has turned out nice.

My last build I threw it together as fast as I could and of course when I was done it looked like a erector set. Ive been splicing wires to trim up some of the extra clutter and taking my time on this one. Will post pics soon.

I think im going to try a set of e-bikekit torque arms. I cant figure out how I can use the Pair of Doc's that I have.

Ken
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Sat Dec 31, 2011 6:50 pm

These seem interesting
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Re: Second Build Trek Fuel EX 5.5

Postby Pure » Sun Jan 01, 2012 2:11 pm

You said Doc's interferes with the derailer? I'm guessing you are putting them on both sides of the drop outs? I would only run one before I trusted the one you linked. Torque arms follow the ol adage K.I.S.S., Keep it simple stupid. In other words, the more points of failure you add the higher the chances of a failure. At your power levels, one torque arm on only one side should be enough. As long as you are under 72 volts, I wouldn't sweat it.

Now to Doc's torque arm. Can you not grind down the part that gets in the way? Or is it not that simple?
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I'm polymerized tree sap and you're an inorganic adhesive, so whatever verbal projectile you launch in my direction is reflected off of me, returns to its original trajectory and adheres to you. So there!
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Sun Jan 01, 2012 4:12 pm

The dropouts on the new frame arent flat like the old set I had. There are dips and curves which does not allow Docs to sit flat. I dont believe I can get enough surface area to mount the TA. I thought about bending the arms out and mount it on the inisde of the drop outs instead of the outside. Is this the way to do it, or perhaps order a new torque arm.

Ken
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Mon Jan 02, 2012 11:07 am

Heres a few pictures of my drop outs.

Image
Image
Image
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Mon Jan 02, 2012 12:26 pm

Image
Image
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Mon Jan 02, 2012 4:14 pm

I ordered the epoxy dp420 from ebay.
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Mon Jan 09, 2012 11:30 am

Image
Image
Image
Image
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Re: Second Build Trek Fuel EX 5.5

Postby MikeFairbanks » Mon Jan 09, 2012 6:49 pm

Niiiice!
Stay frosty
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Wed Jan 11, 2012 5:06 pm

Thanks Mike.

Love the new setup!
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Re: Second Build Trek Fuel EX 5.5

Postby Pure » Thu Jan 12, 2012 5:00 pm

Looks really nice. How's that seat treating you?
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Thu Jan 12, 2012 9:36 pm

Nice cushy seat!

I just got finished installing a pair of Schwabe Big Apple Tires, and ordered some more lipo.

Pictures coming.
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Re: Second Build Trek Fuel EX 5.5

Postby gasfreeearth » Tue Jan 17, 2012 11:33 am

Awesome Bike!! :)
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Tue Jan 17, 2012 9:13 pm

Thanks Man,

Do you think that pushing 24s is too much for both the ebike.ca 72volt controller and the hs3540?

Am I nuts or is this new harness I made insane?

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Re: Second Build Trek Fuel EX 5.5

Postby Spicerack » Tue Jan 17, 2012 9:42 pm

:shock:

Umm...

Go for it! Not sure how toasty the motor will get tho :wink:
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Re: Second Build Trek Fuel EX 5.5

Postby Pure » Thu Jan 19, 2012 1:37 pm

You should be fine, just watch it on long hills. Thankfully there are very few hills in Central Florida, but the ones I do remember, I seem to remember them being pretty long. So on those, I would monitor how hot your motor is getting. At your power levels a BBQ temp sensor installed on your hub, might be a good idea.
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I'm polymerized tree sap and you're an inorganic adhesive, so whatever verbal projectile you launch in my direction is reflected off of me, returns to its original trajectory and adheres to you. So there!
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Thu Jan 19, 2012 3:27 pm

Thanks!

I'll have to find some posts on the bbq sensor mod.
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Re: Second Build Trek Fuel EX 5.5

Postby Spicerack » Thu Jan 19, 2012 10:03 pm

sflorlando wrote:Thanks!

I'll have to find some posts on the bbq sensor mod.


Just done it on my hub. Take bbq temp prong apart- it's usually glued together. Remove the metal prong, the thermocouple usually just slides up insde this. Cut or unsolder the fine enamelled wires for the thermocouple from the pcb. Run a two core wire to the hub inners. Epoxy the thermcouple in place so that it contacts the windings/stator near the phase wires. Carefully solder new wires to thermcouple, use heatshrink to cover the joins. Run two core cable to handlebars, solder onto the bbq temp sensor pcb, re-assemble and use.

Simple really.

It's in my mac repair thread in my sig.
Norco Shore2
Was Cellman MAC rear oil cooled then 8x8 9C vented and temp probed now 9x7 9C vented and temp probed!
12 FET controller
62V 18650 home made battery pack
50 km/h
http://endless-sphere.com/forums/viewtopic.php?f=6&t=32769
MAC Repair thread http://endless-sphere.com/forums/viewtopic.php?f=2&t=34806
Oil cooling the MAC hubbie http://endless-sphere.com/forums/viewtopic.php?f=2&t=37972
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Re: Second Build Trek Fuel EX 5.5

Postby sflorlando » Fri Jan 20, 2012 9:08 am

Cool...I'll check it out
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