Keyne's DH Comp Build - now with liquid cooled HX35! :)

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keyne   100 W

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Keyne's DH Comp Build - now with liquid cooled HX35! :)

Post by keyne » Mar 16 2011 6:10am

I've built a few ebikes before but I'm finally building a powerful off-road bike for myself. (Not everyone can afford a Bomber! :wink: )

Here it is before I started work on it. It's a 2003 Giant DH Comp.
orig_rhs.jpg
orig_lhs.jpg
orig_front.jpg
I never knew quite what a true DH bike was like before I bought this one. Amazing to ride downhill, but not so amazing to ride on the flat and uphill :wink: . So perfect for converting to an ebike! :mrgreen:

Current bike has:
190mm Front travel (Mazzocchi DC Shivers)
215mm Rear travel (6 way Manitou SPV)
44T front chainring and bash gaurd

Plan is:
15AHrs 24s lipo (mounted in triangle- yes it fits)
Crystalyte 5305 or HT3525
Lyen 18fet controller (80-90Amps)
6 pot Gatorbrakes
Fiberglass/carbonfiber moulded side panels
Custom speedo/display
Custom BMS.
9 speed freewheel
9 speed sram gripshift (on left, throttle on right)

Fresh paint job (blue, black and exposed carbon fiber)

I'll use this thread to document the build and the first two posts to maintain a summary.
Last edited by keyne on Feb 07 2012 6:38am, edited 7 times in total.

keyne   100 W

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Re: Keyne's DH Comp Build

Post by keyne » Mar 16 2011 6:12am

Reserving this for overall progress summary.

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Re: Keyne's DH Comp Build

Post by keyne » Mar 16 2011 6:26am

Task number 1 - Dropouts

I took DoctorBass's DH comp build for inspiration:
http://www.evalbum.com/3406
http://endless-sphere.com/forums/viewto ... 3&start=75

Infact I did more than that I bought a spare set of his dropouts! :wink:

Except I made some mods - I wanted the drop-out to clamp the axle so I found a friendly machinist and enlisted their assistance.
bare_dropouts.jpg
Bare Dropouts
bare_dropouts.jpg (93.06 KiB) Viewed 866 times
Image
lhs_droput_bottom.jpg
Left hand side dropout bottom
lhs_droput_bottom.jpg (52.82 KiB) Viewed 9804 times
rhs_dropout_bottom.jpg
Right hand side dropout bottom
rhs_dropout_bottom.jpg (46.13 KiB) Viewed 9621 times
One side of the packman part is welded to the main plate and a bolt allows the axle to be clamped.

I also got him to drill and tap three holes on each side for bolts to attach to the swing-arm.

To make them line up right with the axle I had to put a slight bend in them.
Last edited by keyne on Mar 16 2011 3:28pm, edited 1 time in total.

Ariane   10 kW

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Re: Keyne's DH Comp Build

Post by Ariane » Mar 16 2011 7:53am

Hi,

Nice plan you will out perform a bomber in term of range speed and torque with this set up nice choice :wink:

Good day!
Black Arrow

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voicecoils   10 MW

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Re: Keyne's DH Comp Build

Post by voicecoils » Mar 16 2011 7:54am

Great bike and electrical component choices!

I think an 'H' series motor would be perfect with a high voltage build.

Your photography is fantastic, keep taking photos along the way!

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Re: Keyne's DH Comp Build

Post by chroot » Mar 16 2011 10:39am

I agree with voicecoils's comment. Go get xlyte HS (high speed) or HT (high torque) hub motor on your pretty DH bike.

Your DH bike is so beautiful! 8)
Thank you Justin Lemire-Elmore - You are a HERO!

Tidalforce, Yuba Mundo V4 Cargo bike, Juiced Riders ODK V1 Cargo bike
English is my secondary language - ASL (American Sign Language) is my primary.

keyne   100 W

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Re: Keyne's DH Comp Build

Post by keyne » Mar 16 2011 3:43pm

Thanks for your comments guys, I've already got a 5305 but also have a HT3525 on order :wink: (I don't want to go over about 60-65kmhr)

I'm a bit further ahead on the build than the build log so I'll keep posting till I catch up.

Next step
I took to the swingarm with my angle grinder, (there's no going back now!)
lh_swingarm.jpg
Left hand side of swingarm after grinder attack
lh_swingarm.jpg (76.62 KiB) Viewed 9558 times
rh_swingarm.jpg
Right hand side of swingarm after grinder attack
rh_swingarm.jpg (93.55 KiB) Viewed 9558 times
Following DoctorBass's recommendations I picked up some 3M DP460 Epoxy (has crazy shear strength properties) and will use it to back up the bolts for attachment of the new drop-outs to the swingarm. I guess the picture says it all :D
3M_epoxy.jpg
Attachemnt method

keyne   100 W

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Re: Keyne's DH Comp Build

Post by keyne » Mar 16 2011 7:47pm

After epoxying the dropouts on everything is amazingly solid.
Image
Attachments
rh_swingarm_after.jpg
swing arm after epoxy
rh_swingarm_after.jpg (189.21 KiB) Viewed 866 times

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Doctorbass   100 GW

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Re: Keyne's DH Comp Build

Post by Doctorbass » Mar 16 2011 8:05pm

Keyne, That's a very nice project!

I see the improvement on the dropout, it will allow you to use the regen without any mecanical problem!

After i finished my dropout assembly on the DH comp, i realized that it was a bit OVERKILL.. but i know it will never break!

Any 10mm AXEL would torsion and break before the steel dropout would show any sing of stress!

What was the most difficult was to keep both dropout ( left and right) perfectly aligned with their slit aligned and ensure that the wheel is in the perfect alignement on the swing arm. But i took the time to do that.

I'm looking forward for your project!

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
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GCinDC   10 GW

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Re: Keyne's DH Comp Build

Post by GCinDC » Mar 16 2011 8:34pm

Awesome dropout mod. Inspirational.

Love all that room in the triangle! This is gonna be a sick build!
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Giant DH Comp: 20s lipo (11.6Ah), hs3540, Adaptto Mini-E, 900W BMSBattery charger.
GT I-Drive (sold), 20s lipo, 9C, 72V 45A 12FET.

keyne   100 W

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Re: Keyne's DH Comp Build

Post by keyne » Mar 16 2011 8:40pm

Thanks for the support guys!

DoctorBass - I know what you mean about getting everything perfectly lined up! I spent the best part of 3 hours marking out the mounting holes on the swingarm and on the dropout plates. I also spent ages getting the plates bent to the right angle so the axle would fit just right.

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Re: Keyne's DH Comp Build

Post by dbaker » Mar 16 2011 10:11pm

These are the most secure drop outs /torque arms I have seen. Awesome start to the build :mrgreen:

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Mark_A_W   100 kW

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Re: Keyne's DH Comp Build

Post by Mark_A_W » Mar 17 2011 6:08am

Yay! Another modded DH Team :P


Mine is basically as perfect as a conventional frame converted E-bike can be. It's solid as a rock, with room for batteries.
Under construction: Giant DH Team, MAC Shanghai, Infineon 18 FET controller, 64v Headway battery. LINK!!

Retired: Kona Dawg Dually + Bomber Triple Clamp forks with Nine Continents front hub motor, 48v 10Ah Headway LiFePO4 Pack + 12v 10Ah Headway LiFePO4 booster pack (nominal 64v).

Powered by the sun :)

Dead: Jamis Dakar frame, Mongoose Pro Downhill frame, cooked Lipo booster pack....and various other bits and pieces...

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Re: Keyne's DH Comp Build

Post by Drunkskunk » Mar 17 2011 11:06am

Nice. Love the dropouts. Welcome to team DH
Buy the ticket, take the ride.
Monster Bike:http://endless-sphere.com/forums/viewto ... =6&t=38667

torker   1 MW

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Re: Keyne's DH Comp Build

Post by torker » Mar 17 2011 11:24am

I sure hope you don't mind if I save some pics of those dropouts. :D Elegantly simple. I love it.
Dave When I die I want to slide in sideways yelling WooHoo what a ride !

Giant Rincon w rear 9C 6*10 10s Lipo 30+ amps
Specialized FSR Comp 9C 6*10 15s x 50A 3300 W :)
http://s18.photobucket.com/user/rolinfu ... t=3&page=1

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Doctorbass   100 GW

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Re: Keyne's DH Comp Build

Post by Doctorbass » Mar 17 2011 12:38pm

torker wrote:I sure hope you don't mind if I save some pics of those dropouts. :D Elegantly simple. I love it.

I have some more pics for you right here :wink: :http://endless-sphere.com/forums/viewto ... 3&start=60

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

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Re: Keyne's DH Comp Build

Post by torker » Mar 17 2011 1:19pm

Thanks Doc ! Is it just me or are some pics messed up? I know we lost a bunch( I noticed in the Mag max thread) But now I get a lot of yours that are either half missing or looks like mixed pixels on half ?? Just want to see if it is just me? Don't mean to hijack :oops:
Dave When I die I want to slide in sideways yelling WooHoo what a ride !

Giant Rincon w rear 9C 6*10 10s Lipo 30+ amps
Specialized FSR Comp 9C 6*10 15s x 50A 3300 W :)
http://s18.photobucket.com/user/rolinfu ... t=3&page=1

keyne   100 W

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Re: Keyne's DH Comp Build

Post by keyne » Mar 17 2011 2:38pm

Next Step : Disc Brake adaptor

So I want to use a 9 Speed freewheel which means there is not a lot of space for the disc brake. So I gained about 6mm by having a disc brake adaptor machined like this:
brake_adaptor_back.jpg
Modified disc brake adaptor
brake_adaptor_back.jpg (66.05 KiB) Viewed 5699 times
In retrospect I should have used on of the Avid ones as they are much stronger looking, but I'll see how this one holds up.
brake_adaptor.jpg
Shimano rear brake adaptor mod
brake_adaptor.jpg (88.49 KiB) Viewed 5699 times
Here's how it fits on the dropout:
dropout_plus_brake_adaptor.jpg
dropout plus brake adaptor
dropout_plus_brake_adaptor.jpg (72.52 KiB) Viewed 5687 times
There is only 3mm of thread left at the back of the brake adaptor (the front of the brake adaptor and the dropout are unthreaded holes) so there is not much there, but it seems to be ok.

keyne   100 W

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Re: Keyne's DH Comp Build

Post by keyne » Mar 17 2011 2:43pm

I forgot to mention that the reason I've been so careful with making the dropouts is that I have one of the old x5305 motors that have a 12mm diameter axle, not the newer 14mm that most big motors have. As you can imagine 12mm diameter with 10mm between flats doesn't leave much room for error! If I was just using a normal 14mm diameter axle I probably wouldn't have bothered with making them clamp nicely (but now that it's done I'm pretty stoked with them!)

keyne   100 W

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Re: Keyne's DH Comp Build

Post by keyne » Mar 21 2011 12:43am

While I had the frame apart, I bought a bearing replacement set of Voicecoils who had it left over from his DH team build.
Suspension runs really smooth now! :D
replacement_bearings.jpg
Replacement Bearings for Giant DH Comp
replacement_bearings.jpg (119.45 KiB) Viewed 5655 times

keyne   100 W

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Re: Keyne's DH Comp Build

Post by keyne » Mar 21 2011 6:41am

Had a chance to do some painting through the week and on the weekend. Swing arm, frame, forks, motor and controller. :D
frame_spray.jpg
Frame and swing arm painted
painted_forks.jpg
Painted Forks
painted_forks.jpg (140.7 KiB) Viewed 5625 times
motor_panels.jpg
painted motor covers
motor_panels.jpg (151.78 KiB) Viewed 5625 times
controller_painted.jpg
painted lyen controller
controller_painted.jpg (136.63 KiB) Viewed 5625 times
lyen_cont_bot.jpg
lyen_cont_bot.jpg (114.3 KiB) Viewed 5637 times
lh_dropout_paint.jpg
left hand dropout post painting
lh_dropout_paint.jpg (108.79 KiB) Viewed 5637 times
rh_dropout_paint.jpg
right hand dropout post painting
rh_dropout_paint.jpg (104.55 KiB) Viewed 5637 times

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voicecoils   10 MW

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Re: Keyne's DH Comp Build

Post by voicecoils » Mar 21 2011 6:43am

keyne wrote:While I had the frame apart, I bought a bearing replacement set of Voicecoils who had it left over from his DH team build.
Suspension runs really smooth now! :D
Nice!!! I'm stoked to see them getting used :D

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voicecoils   10 MW

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Re: Keyne's DH Comp Build

Post by voicecoils » Mar 21 2011 6:44am

keyne wrote:Had a chance to do some painting through the week and on the weekend. Swing arm, frame, forks, motor and controller. :D
frame_spray.jpg
Looking good.

Did you see a serial number anywhere on the frame when you tore it down?

keyne   100 W

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Re: Keyne's DH Comp Build

Post by keyne » Mar 21 2011 6:54am

Hmm.. I'm pretty sure there was a serial number under the bottom bracket but I didn't really pay attention. Why do you ask?

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Mark_A_W   100 kW

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Re: Keyne's DH Comp Build

Post by Mark_A_W » Mar 21 2011 3:20pm

Hey Keyne

Does your frame have a serial number on it? If so, where is it?

I can't find one on mine and the insurance company needs it for me to add it to the household contents insurance ($50 for $2000, insured against theft away from the home).

My bike has the controller and battery box stuck to it, so I can't say for sure that it's missing completely, but I sure can't find the serial number :cry:
Under construction: Giant DH Team, MAC Shanghai, Infineon 18 FET controller, 64v Headway battery. LINK!!

Retired: Kona Dawg Dually + Bomber Triple Clamp forks with Nine Continents front hub motor, 48v 10Ah Headway LiFePO4 Pack + 12v 10Ah Headway LiFePO4 booster pack (nominal 64v).

Powered by the sun :)

Dead: Jamis Dakar frame, Mongoose Pro Downhill frame, cooked Lipo booster pack....and various other bits and pieces...

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