Road bike conversion 350W with in-frame batteries

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DvH   10 µW

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Road bike conversion 350W with in-frame batteries

Post by DvH » Jun 24 2019 2:42am

Hi, i would like to share my 1st E-bike build. Tried to have it as minimalistic as possible. Spec:
Shimano TACX road bike
Aikema 350W rear hub motor, in 700C wheel. 6S06 controller
Battery 10S2P configuration. 21700 type Samsung 50E. Divided in 3 separate packs to fit in the tubes of the frame: 2x7 + 1x6 with BMS (more than enough to do the 25km commute)
Thumb throttle only
Total weight 15 kg
Motor assist up to 41 km/h
Attachments
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Einsgruber   10 µW

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Re: Road bike conversion 350W with in-frame batteries

Post by Einsgruber » Jun 24 2019 6:21am

:D :D :D wow this is a lush build... Ive been planing something like this for my bike which is similar

https://www.bikeradar.com/news/boardman ... lideshow=1

I just need to find a small enough hub like the Aikema 350W but that has a disc adapter If you don't mind me asking where did you source yours and is it 24 or 36v?

Many thanks

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E-HP   100 kW

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Re: Road bike conversion 350W with in-frame batteries

Post by E-HP » Jun 24 2019 9:22am

Can you share more details about how you got the batteries into the frame tubes?

DvH   10 µW

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Re: Road bike conversion 350W with in-frame batteries

Post by DvH » Jun 24 2019 10:33am

The battery cells are inserted via holes in the front vertical tube with removed stem. The 3th one goes in the tube with removed seatpost. Not the best servicability but we’ll see...
1ADE7743-5E08-4905-BF34-7A040FD9039A.jpeg
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Drunkskunk   100 GW

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Re: Road bike conversion 350W with in-frame batteries

Post by Drunkskunk » Jun 24 2019 11:15am

That is impressive.
Buy the ticket, take the ride.
Monster Bike:http://endless-sphere.com/forums/viewto ... =6&t=38667

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E-HP   100 kW

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Re: Road bike conversion 350W with in-frame batteries

Post by E-HP » Jun 24 2019 11:45am

DvH wrote:
Jun 24 2019 10:33am
The battery cells are inserted via holes in the front vertical tube with removed stem. The 3th one goes in the tube with removed seatpost. Not the best servicability but we’ll see...
Cool. I guessed the seatpost part looking at your cable routing, but wouldn't have guessed the top tube part of the pack. Is that little circuit board in the bag the controller?

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icherouveim   1 kW

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Re: Road bike conversion 350W with in-frame batteries

Post by icherouveim » Jun 25 2019 7:26am

Great Job!
Now you can race your friends or other bicycles without for them to know!

JimmyJazz   1 mW

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Re: Road bike conversion 350W with in-frame batteries

Post by JimmyJazz » Jun 25 2019 2:50pm

Very nice -- clean & subtle. I've always wanted to do the battery-in-frame, but I think you're the first DIYer that I've seen actually do it.

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Matador   10 kW

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Re: Road bike conversion 350W with in-frame batteries

Post by Matador » Jun 25 2019 9:24pm

What he said ^
Super nice stealthy eBike!
Thumbs up!👍

DvH   10 µW

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Joined: Jun 24 2019 1:26am

Re: Road bike conversion 350W with in-frame batteries

Post by DvH » Jul 19 2019 3:52am

Had Some issues with the tire alignment on the new rim so decided to respoke the motor into the original rim. Problem solved and looks better too..
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E-HP   100 kW

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Re: Road bike conversion 350W with in-frame batteries

Post by E-HP » Jul 19 2019 10:35am

DvH wrote:
Jul 19 2019 3:52am
Had Some issues with the tire alignment on the new rim so decided to respoke the motor into the original rim. Problem solved and looks better too..
Blend in even more. :thumb:

How do you charge (in bike?)?

flat tire   1 MW

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Re: Road bike conversion 350W with in-frame batteries

Post by flat tire » Jul 19 2019 12:02pm

Nice battery. Very creative. Your next mod should be a seat tube motor that connects to a special bottom bracket for total stealth. You can buy that off the shelf actually search "seat tube motor". It goes INSIDE the seat tube.

DvH   10 µW

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Re: Road bike conversion 350W with in-frame batteries

Post by DvH » Jul 21 2019 2:27pm

E-HP wrote:
Jul 19 2019 10:35am

How do you charge (in bike?)?
There is a charge connector inside the saddlebag, where also the BMS and controller are placed

cwah   10 GW

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Re: Road bike conversion 350W with in-frame batteries

Post by cwah » Sep 22 2019 10:41am

Looks nice.

How harder is it to ride?
Help me find my stolen electric brompton: http://bit.ly/1a0vbBC and Bosch Sinus B3 http://bit.ly/1eV0WQz

Turbotd04   100 mW

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Joined: Nov 17 2018 2:06pm

Re: Road bike conversion 350W with in-frame batteries

Post by Turbotd04 » Sep 30 2019 2:34pm

Nice! Proper stealthy

DvH   10 µW

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Joined: Jun 24 2019 1:26am

Re: Road bike conversion 350W with in-frame batteries

Post by DvH » Jul 08 2020 5:54am

small update:
upgraded to 48V (added cells in downtube)
repaint
3D printed cable routing brackets
Attachments
IMG_1813.jpg
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IMG_1814.jpg
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Wolfeman   100 W

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Location: West Coast USA

Re: Road bike conversion 350W with in-frame batteries

Post by Wolfeman » Jul 11 2020 11:46am

Very cool build dude, clever.
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maanebedotten   100 W

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Re: Road bike conversion 350W with in-frame batteries

Post by maanebedotten » Jul 11 2020 12:27pm

That sure is a most impressive build.

I would love some more info on how you made the holes in the headset tube.
Any worries about the structural integrity of the tube?

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