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Fatbike with 3500w Bafang G510 Ultra max

Posted: Sep 20 2020 10:19pm
by Sinhu
Hi !

My fatbike build have started, and i’m planing to post the process to working bike.

I starded with a frame i got used, sanded and painted it.

The frame came from this bike:
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Momas f1000
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Used bedliner paint
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Titanium shell paint
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Paint job went very well
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Finish
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Finish
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Finish
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Painted feontfenders to
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Front fender
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Back fender is plastic
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Fender for the backwheel
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Motor i have orderd from Innotrace in Germany, that is the developer and supplier to wattwagon that offer the 2500w version, Innotrace have upgraded version of this controller that gives 3500w of power with 52v80Amp controller
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Wattwagon
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A callange is battery, and orderd the biggest downtube battery case on the marked. Polly with room for 91 cells
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Polly downtube
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Have found a drawing of fiting 98 cells in this battery case, that means 14s7p 98cells and are going ro use a 50A BMS. Do not think i will be other then some second above 50A and peak A is 120A so i think i’ll be fine.
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Polly with 98 cells
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Daly BMS
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Bms
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Not 100% sure, but looks like it will be Samsung 18650 30Q cells i will use. And if i can fit 98cells in 7p i will have a battery with 52v21Ah
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Samsung 30Q
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As i wait for motor and rest of the part i have startet to fit some parts. Today i’m fiting backfender.
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Fiting back fender
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Found some prefabricated holes, proberly for draining the frame tube pipes. Was perfect for mounting the fender after treading the holes with M5:)
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Treaded prefab holes With M5
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Treaded prefab holes
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Front suspension i desided on trying the upside down design as DNM US6 15x150mm thru axl.

I struggled to find a suspension fork with 15x150mm for strait frame tube, only tapperd fork was availble for fatbike. Solution was a semi integretad head bearing.
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Head bearing
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Suspension upside down design
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The head bearing set is in place.
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Headset
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Trying on the front wheel, think it’s looks good :)
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Wheels on bike
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Found the wheels at XXL with reflecting rim tape, 90 mm thru axel 15x150mm front and 12x190mm rear
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White 90mm rims
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Fitting a seatpost with suspesion, simpel and cheap but a sweet extra on a hardtail :)
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Suspension seatpost
DC07D0FA-CA95-4D74-8ED0-C558F2B61463.jpeg (160.38 KiB) Viewed 534 times
With the frontsuspension it’s a bit problematic to mount it. Found a cheap extender bolt for the head tube with a mounting bracket.
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Mounting solution
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Need to find some rings for the suspension arms to screw the suspesion rod’s from the fender.

And with the frontlight mounted on the bracket it looks clean :)
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Front fender with Supernova E3 frontlight
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As the Innotrace controller dont have light support, the solution was a Supernova E3. With this frontlight i can run power directly feom the battery (12-60v) with a line out 6v to rearlight and a on/off push button.

The big polly battery case arrived today :)

Re: Fatbike with 3500w Bafang G510 Ultra max

Posted: Sep 21 2020 9:26am
by HoraceLai
Fenders look really good. Where did you buy them?

Re: Fatbike with 3500w Bafang G510 Ultra max

Posted: Sep 21 2020 10:39am
by Sinhu
Hi !

The fenders i had to order feom the uk.
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Web adr fenders
D36567FA-1E3F-4719-A53F-8A441D159569.jpeg (122.75 KiB) Viewed 606 times

Re: Fatbike with 3500w Bafang G510 Ultra max

Posted: Sep 28 2020 3:44am
by Sinhu
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Test fitting the new battery case
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The big polly battery case

Not much more room, fits perfect :)
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Big polly battery
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Today the cells arrived. The prodjekt i starting to come together :)
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Samsung INR18650-30Q
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Very positiv test of the 30Q cell
https://lygte-info.dk/review/batteries2 ... %20UK.html


Starting to mount breaks and gear on the bike.
For breaking i have desided on Shimano 203mm breakdisk front and rear.
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Shimano SM-RT76L 203mm breakdisk
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And 4 piston break calipre.
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Shimano BR-MT 520 4 piston calipre
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Shimano BR-MT 520 4 piston calipre
CE6E561E-6C99-432E-AB39-5B5DBB284236.jpeg (128.7 KiB) Viewed 301 times
You find more expensive breaks but i hope these will do the job.

Break levers i use Shimano Deore with mount for a SLX 10speed shifter.
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SLX shifter 10speed on BL-M615 break leaver
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Shifter mount on breakleaver
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The controller from Innotrace do not have out put for front and rear light, so i try connect some lights i found on aliexpress.

First i try to find a place for the DC-DC step down and fuse.
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Dc-dc stepdown to 12v and fuse fit inside left motorcover
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And i need a switch
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On and off swith
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For front light i use a Led light in a aluminium casing
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Led lights in alu casing
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Rear light i will use a led strip on both side of the rear wheel
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Led strip
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Rear light
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Still waiting for motor and battery, and it will take 2-3 weeks before every thing is here.

But some small parts and nick nack lands in the mailbox from china :)
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Platform MTB pedals
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Re: Fatbike with 3500w Bafang G510 Ultra max

Posted: Sep 30 2020 7:55am
by BeachRider2016
I ordered the same battery case to build a 14s 98 cells pack as well. Followed.

Re: Fatbike with 3500w Bafang G510 Ultra max

Posted: Oct 01 2020 4:49pm
by Sinhu
Have seen a couple of drawing of 98cell version, but fitting a 60+A BMS as well seems difficult.

Would love seeing your solution

Re: Fatbike with 3500w Bafang G510 Ultra max

Posted: Oct 05 2020 11:18am
by Tomblarom
Hey guys, I'm that person, who designed the layout. Haven't got time to 3D-print the parts yet and test fit everything. Going to give feedback and publish the whole design soon.
https://photos.app.goo.gl/zHAfkTd9oUuBhV2t8

For the BMS, I use this chinese Smart BMS with BT and replace the MOSFETS and shunts to easily achieve 60A, while having a max height of 10mm. Excited to see how this works out.

I'm using VTC6 and discharge with a max of 50A. Having 7P, each cell won't reach more than ~7A. This keeps the cells temperature pretty low. Check the discharge/temperature chart, of the cell you're planning to use. Otherwise stay safe and build an 14S6P or 13S7P.

Re: Fatbike with 3500w Bafang G510 Ultra max

Posted: Oct 05 2020 12:10pm
by Sinhu
I’m sorry not credit your design, i will of course delete the drawing from the post if you prefere ?

Or you can ad to this tread with your battery build and progress fit 14s7p in the big polly case ?

No bad intesion using your design, just impressed bye the creativety :)

Re: Fatbike with 3500w Bafang G510 Ultra max

Posted: Oct 17 2020 10:21pm
by BeachRider2016
Tomblarom wrote:
Oct 05 2020 11:18am
Hey guys, I'm that person, who designed the layout. Haven't got time to 3D-print the parts yet and test fit everything. Going to give feedback and publish the whole design soon.
https://photos.app.goo.gl/zHAfkTd9oUuBhV2t8

For the BMS, I use this chinese Smart BMS with BT and replace the MOSFETS and shunts to easily achieve 60A, while having a max height of 10mm. Excited to see how this works out.

I'm using VTC6 and discharge with a max of 50A. Having 7P, each cell won't reach more than ~7A. This keeps the cells temperature pretty low. Check the discharge/temperature chart, of the cell you're planning to use. Otherwise stay safe and build an 14S6P or 13S7P.
Please do post the 3d printed spacers when it’s done. I got my case in the mail today and itching to get it assembled. :mrgreen:

Re: Fatbike with 3500w Bafang G510 Ultra max

Posted: Oct 18 2020 2:50am
by Tomblarom
I added pictures to the Google photos album. Have a look! It was simply not enough space... my 3D printer was not precise enough and my cells had 18,3mm diameter. Maybe you are able to bring this to work :)

EDIT: Published my designs. https://www.thingiverse.com/thing:4627055