Pictures of my first build

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dpe743   10 mW

10 mW
Posts: 30
Joined: Oct 22 2015 3:34pm
Location: Northern Illinois, USA

Pictures of my first build

Post by dpe743 » May 19 2016 11:50am

So now that I've completed my first build, and tested it for a few miles thought I'd share some pictures.
charge_full.jpg
I started off with a Charge Plug (2015, steel frame, Sora 2x9 groupset). I chose this bike because I wanted a good road bicycle (in general, pre-ebike), and for the price ($600) it included a decent set of components and disc brakes. Also, something about the brand name "Charge Plug" and e-bikes go together.

The bottle battery (from Luna -- Great support guys, thanks) ended up taking more space than I envisioned -- I probably should have gotten the shark pack (I don't think anyone will be fooled into thinking this is an actual water bottle :roll: )
I found a way to solve the issue of where to put the throttle. I found an "accessory mount" -- this one made by Topeak, it is essentially an adjustable T bar that attaches to the handlebars. However, had an issue in that the diameter was too wide for the throttle. So I epoxied a small piece of a 7/8 inch wood doll rod to the end and also wrapped the exposed wood with tape.
drop_throttle.jpg
This puts the throttle in the right position to reach with my ring finger, when I've got my hands on the horns (my normal riding position).
I also moved the headlight to the accessory bar, and put the Cycle Analyst on the main handlebar.

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parajared   10 kW

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Joined: Apr 16 2012 11:33pm
Location: Northern Arizona

Re: Pictures of my first build

Post by parajared » May 19 2016 3:11pm

Very nice!
How does it feel peddling the thing with the motor and battery strapped to it vs the regular tire and no battery?

dpe743   10 mW

10 mW
Posts: 30
Joined: Oct 22 2015 3:34pm
Location: Northern Illinois, USA

Re: Pictures of my first build

Post by dpe743 » May 19 2016 9:53pm

parajared wrote:Very nice!
How does it feel peddling the thing with the motor and battery strapped to it vs the regular tire and no battery?
When I first hooked the wheel up, I had this sick feeling of "What did I do to this smooth machine?" However, since the battery took about another week to arrive (due to hazmat shipping), I was riding it without power during that time -- and it rode about like it did before. That is once I re-adjusted the disc brake (it was rubbing slightly with the new wheel). So at least that fear was alleviated.

Now with the battery mounted, there is some extra weight but nothing like the extra pounds that I'm carrying around the waistline. So overall I'd say it was worth converting a road bike (although this was no super racer before, but better than any bike I've had in the past).

There's just two thing I've got to figure out yet. I need to finish fabricating the cadence ring (the Sora sprocket screw holes are spaced too far for the one that came with the kit). And I need to figure out how to make an ebrake. For that -- I'm thinking of gluing a couple pieces of thin aluminum at the top of the brake levers, and running wires from them to the ebrake sensor. Once I get that figured out I'll update the pictures above with what I come up with. (I'm assuming that the ebrake sensor should be a normally closed switch that opens when the brake is applied -- if it is the opposite, I'll have to run it through a normally-open relay).

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Grizzl-E   100 W

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Joined: Jun 01 2015 9:57pm
Location: Manitoba, Canada

Re: Pictures of my first build

Post by Grizzl-E » May 19 2016 11:06pm

Ebrakes are typically normally open. You can buy hall sensors (or reeds) on ebay to do what you want. You just glue a magnet nearby.


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Gregory   100 kW

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Joined: Jul 27 2007 9:18pm
Location: Perth, Western Australia

Re: Pictures of my first build

Post by Gregory » May 20 2016 12:02am

You don't need brake sensors, but if you want one the HWBS or Hidden wire brake sensor is unobtrusive.


1) x5305 Hub Motor in a 24" Sun rim with 10G spokes, Kelly 72601 controller, 74V 10Ah Turnigy LiPo 20C Battery and CycleAnalyst
2) Mac 10T rear hub in a 700C "comfort bike" 15S 5Ah LiPo, stock 28A Xie Cheng controller
3) 38" Longboard, Turnigy 6374, CC Mamba XL2 ESC

Raged   1 kW

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Joined: Jan 02 2014 12:15pm
Location: Melbourne, Australia

Re: Pictures of my first build

Post by Raged » May 23 2016 6:17am

Always good to see other options for people who like using dropbars. How do you like the placement? I put mine on the left hand close to the bar so I can use my thumb to throttle up. Keeps the cockpit clear and keeps the thing stealth from the front.

*edit I personally dont run brake senors. You only need them if you run PAS.

Image
Focus Black Forest 29er - MAC10T 14S Lipo - 50km/h, 50km range. (dead)http://endless-sphere.com/forums/viewto ... 91&start=0
Cube Reaction 29er Cyclocross BBS02 http://endless-sphere.com/forums/viewto ... =6&t=70549

dpe743   10 mW

10 mW
Posts: 30
Joined: Oct 22 2015 3:34pm
Location: Northern Illinois, USA

Re: Pictures of my first build

Post by dpe743 » May 25 2016 11:12am

Raged wrote: How do you like the placement?
It works out better than I thought -- hitting it with my fingers is about as easy as with a thumb. I do end up using the cruise control function sometimes so I can move my hands to the top bar on longer road stretches. Hence the desire to hook up an e-brake.

heavymetalthunder   100 W

100 W
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Joined: Oct 07 2013 9:46pm

Re: Pictures of my first build

Post by heavymetalthunder » May 25 2016 1:50pm

Nice build. Be sure to install head and tail lights. As you will probably be riding much faster and drivers won't really see you.

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