Selfmade E-Hardtail (Just have a look ;)

Show off your E-bike creation here.
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Zeurus   10 mW

10 mW
Posts: 22
Joined: Sep 09 2018 10:02am

Selfmade E-Hardtail (Just have a look ;)

Post by Zeurus » Dec 07 2019 3:20pm

Hey guys,

after our last projekt, where we built in a motor in our normal bikes (signature), we decided to do it right, from the beginnig till the end.
So we ended creating our new bike in CAD. After endless hours of planing and manufacturing with CNC machines were really proud what came out. :D Till now we drove 950km (with about 30000 meters in hight) in the Mountain of Tyrol/Austria. Mostly driving trails and steep technical stuff.
Building time was about 6months from march till august for 2 bikes.


Some Facts:
* hardtail - EN-Al6060 / 6026 welded, hardened, sandblasted and painted
* tyres: 27.5*2.8inch - tubeless
* fronttravel: 160mm
* weight: 30kg
* motor: 6.5kw peak and about 3.5- 4kw continious power (modified LMX30mm 2019 Motor)
* battery: 144x Samsung 29E Cells -> about 1.5kwh with bms
* range: 60-90km with 1500-2500hm (on the flat... dont know^^)
* controller: Nucular 12F Controller (Amazing work Vasily!)
* 2 halftwist throttles: acceleration right side and recuperating on the left
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27.5''plus Hardtail :wink:
viewtopic.php?f=6&t=103637

26'' Fully with 6374 and VESC
viewtopic.php?f=6&t=99610

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e-beach   1.21 GW

1.21 GW
Posts: 3510
Joined: Jan 10 2012 9:48pm
Location: Any Los Angeles area beach I am at. Or Santa Monica or possibly the south bay beaches.

Re: Selfmade E-Hardtail (Just have a look ;)

Post by e-beach » Dec 07 2019 3:36pm

Very nice work! Does it perform as you intended?

:D :bolt:
Favorite Quotes:
"This is L.A., sugar. There is no 'over the top." Chris Erskine
"At a certain point the entropy wins." Maria Helena Braga

Current Build: ProFlex 757 Expert full suspension. Yescomusa 36v 800w Rear DD, upgraded 10AWG solid core through axle phase wires. 15ah Headway, 1000+ cycles, 80% DOD 30A Tronsung controller.

Past: Trek 4500 Yescomusa 36v 800w front DD.
Liahona, Yescomusa 36v 800w generic front DD.
1992 Trek 800, Yescomusa 800w 36v front DD.

Zeurus   10 mW

10 mW
Posts: 22
Joined: Sep 09 2018 10:02am

Re: Selfmade E-Hardtail (Just have a look ;)

Post by Zeurus » Dec 07 2019 4:21pm

thx:) yeah it behaves really awesome. we did not expect it to be that good. its a big step forward from our ebike conversion we had before.

27.5''plus Hardtail :wink:
viewtopic.php?f=6&t=103637

26'' Fully with 6374 and VESC
viewtopic.php?f=6&t=99610

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DanGT86   10 kW

10 kW
Posts: 982
Joined: Sep 06 2012 9:18pm
Location: Saint Louis MO

Re: Selfmade E-Hardtail (Just have a look ;)

Post by DanGT86 » Dec 07 2019 5:34pm

Absolutely amazing work!!!!! Thanks for posting all this.

Zeurus   10 mW

10 mW
Posts: 22
Joined: Sep 09 2018 10:02am

Re: Selfmade E-Hardtail (Just have a look ;)

Post by Zeurus » Dec 09 2019 3:17pm

Thx DanGT86 :)

and here some CNC- porn XD
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27.5''plus Hardtail :wink:
viewtopic.php?f=6&t=103637

26'' Fully with 6374 and VESC
viewtopic.php?f=6&t=99610

User avatar
DanGT86   10 kW

10 kW
Posts: 982
Joined: Sep 06 2012 9:18pm
Location: Saint Louis MO

Re: Selfmade E-Hardtail (Just have a look ;)

Post by DanGT86 » Dec 09 2019 5:00pm

Nice.

So is the whole stator just pressed into the original lmx housing? Do you press it out or machine the housing down to just a small sleeve to install in your custom housing?

Im pretty impressed with my 30mm lmx motor so far. I rode about 7km of repeated 4kw bursts from a dead stop yesterday. When I was done the stock motor was only 52degC. I bet yours is a beast with the extra heat shedding ability.

Zeurus   10 mW

10 mW
Posts: 22
Joined: Sep 09 2018 10:02am

Re: Selfmade E-Hardtail (Just have a look ;)

Post by Zeurus » Dec 11 2019 12:24pm

yeah its just pressed in.
I did one cut in axle direction on the housing, then is realy easy to take the stator out.

no we measured the exact diameter and then pressed it in again in our housing. (with locktite glue).

yeah maybe now due to cold conditions. in summer with 30degrees its a mess when you drain cont. power. (we always had to wait for cooldown from 100°)
some burst are not the problem. current causes the heat, due to resistance in the phase wires.
4kw at max rpm is less current than 4kw at 30%max rpm.
1kw with 25%max rpm causes nearly the same heat as 4kw at 100%max rpm and 1kw upwards is not that much.

overall its not a bad motor but now its a difference like day and night^^
27.5''plus Hardtail :wink:
viewtopic.php?f=6&t=103637

26'' Fully with 6374 and VESC
viewtopic.php?f=6&t=99610

Grantmac   10 kW

10 kW
Posts: 689
Joined: Oct 22 2018 12:43pm
Location: Victoria, BC

Re: Selfmade E-Hardtail (Just have a look ;)

Post by Grantmac » Dec 12 2019 12:19pm

Any plans for a suspension version? How is the noise level?

Zeurus   10 mW

10 mW
Posts: 22
Joined: Sep 09 2018 10:02am

Re: Selfmade E-Hardtail (Just have a look ;)

Post by Zeurus » Dec 22 2019 8:08am

we considered a fullsuspension bike, but there a view things you have to consider about. espcially if you want recuperation and middrive combined with low weight (sometimes we have to carry the bike upwards difficult steep paths). maybe out of a mood this following year but not planned. currently were planning a strong headlight for this dark winterdays :)

noice level is generally good with fresh o-rings installed on the drive sprocket. They're lasting about 150-200km till they wear out, then its as loud as on the vid i've posted. but not uncomfortable on the bike.
27.5''plus Hardtail :wink:
viewtopic.php?f=6&t=103637

26'' Fully with 6374 and VESC
viewtopic.php?f=6&t=99610

Zeurus   10 mW

10 mW
Posts: 22
Joined: Sep 09 2018 10:02am

Re: Selfmade E-Hardtail (Just have a look ;)

Post by Zeurus » Dec 23 2019 6:04am

riding upwars a skiresort on the piste is fun! :)
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27.5''plus Hardtail :wink:
viewtopic.php?f=6&t=103637

26'' Fully with 6374 and VESC
viewtopic.php?f=6&t=99610

bikerpete   10 W

10 W
Posts: 85
Joined: Jan 27 2020 9:09pm

Re: Selfmade E-Hardtail (Just have a look ;)

Post by bikerpete » Apr 05 2020 5:53am

Nice job, it's set a bit of a benchmark for me.

I've had my 30mm LMX apart on the bench for a while as I figure how to achieve what I'm after (fitting a clutch with reduction). I'm getting closer to jumping in and making a new housing as you have.

There's a lot of room in the back of the standard motor, it looks like you must have machined the shaft down too to get that short motor?
How did you go about getting the rotor out and back in again without damaging either magnets or fingers? I've been hesitant to tackle that.

Cheers.

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DanGT86   10 kW

10 kW
Posts: 982
Joined: Sep 06 2012 9:18pm
Location: Saint Louis MO

Re: Selfmade E-Hardtail (Just have a look ;)

Post by DanGT86 » Oct 18 2020 12:30pm

Im using one of these newer style 46kv 30mm Lmx motors with a nucular 6fet. It runs pretty well in FOC but growls and sounds like its losing sync at full rpm unloaded. It also has a slight stutter when i gently apply throttle from a steady cruise.

Do you have any tips or a config file you could share for using this motor with the NUC?

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