48 Volt Rear Hub Build

General Discussion about electric bicycles.
EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Feb 15 2018 7:02pm

Thanks guys, can't wait to ride it :D
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Feb 17 2018 8:11pm

Got the TAs done.
They ended up hand making them. Also a custom washer and 2 x stainless bolts cut to size. All for $50 AU.

Great job I reckon.

https://i.imgur.com/k65BjJO.jpg

https://imgur.com/a/KF00L
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Feb 18 2018 5:00am

And battery done. Just need connectors, I'm thinking XT60 or the Spark resistant XT90s look cool!

https://imgur.com/pmNylix

https://imgur.com/KPNtKSB
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Feb 19 2018 4:18am

Ok, I hooked it all up and the back wheel spins. Happy days :)

Just have to finalise mounting the battery, controller and some cable management.. then should be golden.

Not sure whether to use the brake disconnects/ levers that came with the kit. Do you guys think this is a necessity?
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wturber   100 kW

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Re: 48 Volt Rear Hub Build

Post by wturber » Feb 19 2018 3:49pm

EbikeAus wrote: โ†‘
Feb 19 2018 4:18am
Ok, I hooked it all up and the back wheel spins. Happy days :)

Just have to finalise mounting the battery, controller and some cable management.. then should be golden.

Not sure whether to use the brake disconnects/ levers that came with the kit. Do you guys think this is a necessity?
If not the ones included in the kit, then some other scheme/system that cuts the power to the motor when the brakes are applied or your hands aren't on the handlebars etc.

There's a lot of torque from that motor and it can get out of control fast. Especially when you aren't sitting on the bike. Good use habits are probably the most important thing. But it'd be nice to know that grabbing a brake lever will disconnect power.
Last edited by wturber on Feb 19 2018 7:33pm, edited 1 time in total.
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Feb 19 2018 5:06pm

Good call!
Thanks for the reply, I will use them
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Feb 27 2018 4:09am

Hi all,
Have been super busy! Putting our hoise on the market soon and had heaps to do. I have found time to get out for a couple of rides on this build, around 20 kms clocked up so far.
Will post a completed photo soon.

It's running great and the battery is performing very well, have put a couple of small charges on it and all good.
I have a couple more batteries almost ready to build, 14s 5p LG HE2 and 14s 4p 25R more on those later.

One thing that's not great is the brakes. I'm using the levers that came with the kit and it looks like I need new cables with a larger barrel head?
Can anyone confirm this and do the kit levers use an 8mm barrel head?
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Mar 07 2018 5:54am

Here's a vid of my build.

Thanks for everyone's help/advice it's appreciated :D

https://youtu.be/OC5VsPVyxHk
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Mar 30 2018 12:45am

Updated photo of this build.

Absolutely loving it! Have around 150km on the clock now.

Couple of upgrades since this photo are Suntour NCX suspension seat post and Mirrycycle mirror.

Image
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Mar 31 2018 12:23am

I just discovered a couple of other features the voilamart hub kit has...by accident :lol:

It's not mentioned in the very minimal manual but if you press and hold the down arrow on the button pad it goes into walk mode, so you can walk beside the bike and it propels itself, another long press to disengage.

Also if you press and hold top button it turns on headlight, if you have one. Yet to test this but I just bought some headlights so I may use it :)
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Apr 23 2018 2:39am

Went out for a 15km ride this afternoon, bike is going great.
55 km on flat. 40 km up hill without pedaling, so pretty happy with that.

I'm pretty sure i'll need to take the controller out of the bag though :( as it was almost too hot to touch, which will most likely kill it before too long.

One option I have thought of doing is cutting a vent hole in forward corner of triangle bag and one at other end to get some air flow over the controller. I saw this done somewhere on here but can't find it now.

Where would you mount the controllerif this was your bike?
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Re: 48 Volt Rear Hub Build

Post by torker » Apr 23 2018 6:24am

Looks tight but on the seatpost would make all the cabling nice and short. Might want to build a deflector for the mud/water. Or right in front of the battery bag, nice looking bike btw..
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Apr 23 2018 4:00pm

torker wrote: โ†‘
Apr 23 2018 6:24am
Looks tight but on the seatpost would make all the cabling nice and short. Might want to build a deflector for the mud/water. Or right in front of the battery bag, nice looking bike btw..
I think the seatpost option will be out now as I've added a suntour ncx seatpost.

Might explore the front of bag option.
Thanks for that ๐Ÿ˜
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markz   100 GW

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Re: 48 Volt Rear Hub Build

Post by markz » Apr 23 2018 6:51pm

How does that front mud guard help out?

I have a full length one thats a tad too narrow and rubs on tire.

EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Apr 23 2018 7:43pm

markz wrote: โ†‘
Apr 23 2018 6:51pm
How does that front mud guard help out?

I have a full length one thats a tad too narrow and rubs on tire.
It's just for looks at this stage. ๐Ÿ˜†

Just coming out of a long hot and dry summer here. No wet stuff to speak of. I'll let you know if you like ๐Ÿ˜Š
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Apr 25 2018 2:42am

I decided the best place for the controller is on the tube under the bag.

I hit it with a couple of coats of flat black. This brings the cables as close to the battery and bag as possible.

Not ideal but at least I won't fry the controller :)

I might add some silicone to the joints and where the wires come out just in case.

Image

Image
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Philaphlous   100 W

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Re: 48 Volt Rear Hub Build

Post by Philaphlous » Apr 25 2018 5:13pm

How you like the suspension seat post? I haven't ridden my bike enough to test it out.

EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Apr 25 2018 7:41pm

Philaphlous wrote: โ†‘
Apr 25 2018 5:13pm
How you like the suspension seat post? I haven't ridden my bike enough to test it out.
I like it a lot so far. Takes a little getting used to but def makes a big difference!

Only downside is I have to find a new rear guard now as I can't attach to the seat post. :cry:
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Lurkin   100 kW

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Re: 48 Volt Rear Hub Build

Post by Lurkin » Apr 26 2018 6:21am

Mudhugger guard would be super nice, but its a pretty expensive option.

A guard on the front wheel is the most effective way to keep water off the controller. Failing that a guard over the controller is an option.

If all else fails, and you are caught out in the rain - pinch a dog poo bag from a dog park + electrical tape = water tight....

EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » Apr 26 2018 6:53am

Lurkin wrote: โ†‘
Apr 26 2018 6:21am
Mudhugger guard would be super nice, but its a pretty expensive option.

A guard on the front wheel is the most effective way to keep water off the controller. Failing that a guard over the controller is an option.

If all else fails, and you are caught out in the rain - pinch a dog poo bag from a dog park + electrical tape = water tight....
Yes I've seen the mudhugger. If I can't find anything else i'll probably get one.
Great idea with the dog poo bag! 8)
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Re: 48 Volt Rear Hub Build

Post by EbikeAus » May 14 2018 6:40am

Help I need new brakes!

I'm loving this bike but it has one major flaw!

I currently have mechanical discs and they suck. After using hydraulics on my Giant Roam conversion it's hard to be happy with mech discs.
I'm looking at these as a place to start

https://rover.ebay.com/rover/0/0/0?mpre ... 1848243345
I will probably replace the front first and keep the rear as it has the motor cut out switch.

Are there levers I can buy with the switch, I can only find them for bafang?
Or are they easy enough to diy?

Just saw these, has anyone used them?

https://rover.ebay.com/rover/0/0/0?mpre ... 3129487626

Thanks :)
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Chalo   100 GW

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Re: 48 Volt Rear Hub Build

Post by Chalo » May 14 2018 4:32pm

Are your mechanical discs generic cheap crap? There are good and horrible mechanical discs just like there are good and horrible hydraulics. (But if you give a hearty tug on the lines of both, you'll find that the mechanical ones work a lot better.)

(Also, you'll find that touching a cable to your brake rotor doesn't harm anything, while touching brake fluid to your rotor makes the brake very lame.).

Anyway, the cable brakes that are worth a damn these days are Avid BB7 and TRP Spyke. I'd try those before going for hydraulic, magnetic, pneumatic, optical, nuclear, or any other needlessly gizmodic brakes.
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EbikeAus   100 W

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Re: 48 Volt Rear Hub Build

Post by EbikeAus » May 14 2018 7:44pm

Chalo wrote: โ†‘
May 14 2018 4:32pm
Are your mechanical discs generic cheap crap? There are good and horrible mechanical discs just like there are good and horrible hydraulics. (But if you give a hearty tug on the lines of both, you'll find that the mechanical ones work a lot better.)

(Also, you'll find that touching a cable to your brake rotor doesn't harm anything, while touching brake fluid to your rotor makes the brake very lame.).

Anyway, the cable brakes that are worth a damn these days are Avid BB7 and TRP Spyke. I'd try those before going for hydraulic, magnetic, pneumatic, optical, nuclear, or any other needlessly gizmodic brakes.
Thanks mate ๐Ÿ˜ƒ

Yes I think they are a pretty basic shimano set.
It does seem to make more sense staying with mech discs, that's what I'll do.

So with the two models you mentioned do you know off hand which will have a thinner calliper body as I'm fairly tight between caliper body and motor?

I'll just order discs and calipers and use the cut off levers that came with the kit for now. Would like some nicer ones at some stage if they can be had.
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