Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHOTOS!

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Kent
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Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHOTOS!

Post by Kent » Nov 17, 2012 8:32 pm

First many thanks to Oatnet for giving us the original idea and inspiration, and the great tip about fork mounted clamps :idea: .
In the beginning...
Jamis 1 Original.jpg
Jamis Komodo II- sturdy frame, good fork angle
Jamis 1 Original.jpg (109.63 KiB) Viewed 2058 times
A year later...
24  sideview Jan 13.jpg
24" wheels-front battery case
24 sideview Jan 13.jpg (118.54 KiB) Viewed 1708 times
For info on my downsizing to a 24" moped rear, go here: https://endless-sphere.com/forums/vi ... =3&t=39751
I originally embarked on the front mounted battery idea by working backwards. First I decided that I wanted to go with Lifepo because I wanted plug and play and realized that my memory isn’t what it used to be. Plus I live in an apartment. I recognized the cost and weight penalty. Since I had already experienced a Ping 36 v 15ah on my first bike, and having decided to embark on full 72 volt on my new build, I realized that a 72 v brick would be way too big, so decided to use two separate 36 volt packs hooked together in series.

Next, after having decided on (2) 36 volt 10 ah batteries from Emissions Free, I checked his sizing chart (very handy) and determined what size my front case would have to be for the square brick that I chose.. I just couldn’t find the size I wanted in a Pelican Case and being eager at the bit, found a lighter duty one at the local battery store. Oh well, it got me started.

But there was the problem of how to mount it as it wasn’t sturdy enough to just drill holes with a few bolts, so I came across front mount luggage racks and decided to try one of those. The bottom legs of the rack attached to the fork clamps and the top to the handlebar via a couple of clamps from Amazon.
Battery Box front resized..jpg
The Original $8 Special
Battery Box front resized..jpg (93.54 KiB) Viewed 2261 times
This setup turned out to be not sturdy enough as my front fork, a Marczocchi Bomber, is very stiff and there was too much pounding. The rack broke in several places. Another problem with this fork was limited 100mm travel, so it was best that I keep it stiff as the clamps took 1” off the travel. Details, details.
Fork clamps resized.jpg
Clamps are great but watch out for reduced travel
Fork clamps resized.jpg (104 KiB) Viewed 2261 times
Broken Front Rack.jpg
Tearing it all out-what about planning?
Broken Front Rack.jpg (159.41 KiB) Viewed 2260 times
Well it got me through the summer and I finally located the case I was looking for. Large enough for the battery and some electrics but no larger than necessary. I found it on E-Bay. Perfect size. I was tempted to paint it grey to match the bike but decided that the yellow was such a great attention/safety feature so i kept it.
Stormcase 1.jpg
Yellow can be seen 1/2 mile away
Stormcase 1.jpg (74.01 KiB) Viewed 2261 times
Stormcase 2.jpg
Stormcase 2.jpg (96.73 KiB) Viewed 2260 times
This time around I skipped the front rack idea, and decided to mount it more securely. Attached the top of the case to the handlebars with clamps from Amazon:
Stormcase 9.jpg
Clamps attach to an aluminum bar glued inside the case
Stormcase 9.jpg (88.73 KiB) Viewed 2260 times
The bottom I mounted the case on "L" brackets which are secured to the fork clamps. And keeping in mind the pounding, I cushioned the case by installing rubber isolation biscuits which are secured by bolts which go through the bottom of the case and screw directly into the top of the rubbers which have implanted threaded nuts. On the bottoms of the rubbers are bolts permanantly attached.
Rubber Mount.jpg
Rubber Mount.jpg (38.87 KiB) Viewed 2192 times
Stormcase 10.jpg
Rubber mounts come threaded on the top with bolts on the bottom
Stormcase 10.jpg (144.22 KiB) Viewed 2260 times
The wiring process-strictly Saturday morning at the kitchen table with the latest ideas..
Stormcase 3.jpg
Front Battery On/Off, Headlight Switch, Charging Port
Stormcase 3.jpg (59.86 KiB) Viewed 2260 times
Sitting on a piece of foam, its a tight fit. Someday I'll make up a divider to separate the battery from the electrics.
Stormcase 12.jpg
I Planned to have all the electrics on one side which makes it tight but it works
Stormcase 12.jpg (81.41 KiB) Viewed 2261 times
I was originally going to go with a couple of small LEDs that many have used, but but then I came across this little gem on sale at Northern Tool. It fits on the front of the case really well and is out of the road.
Northern Tool Light.jpg
5" x 5" x 1.25" thick
Northern Tool Light.jpg (57.41 KiB) Viewed 2260 times
Stormcase 7.jpg
With running lights which can be seen from the side
Stormcase 7.jpg (90.42 KiB) Viewed 2260 times
Stormcase 11.jpg
Maybe too bright-we'll see
Stormcase 11.jpg (67.77 KiB) Viewed 2261 times
Remarkable the little 20 watt dc:dc converter from ebikes.ca has held up to all the electrical demands quite well. I wish though that they would upgrade the diameter of the wires.

Edit: Here is a photo of the rear light described furthur down. A terrific light for the $:
Wald basket full.jpg
Back from the Laundry-Wald folding baskets painted so they can't miss me!
Wald basket full.jpg (148.68 KiB) Viewed 2037 times
The second battery box build is here: https://endless-sphere.com/forums/viewto ... &start=350 page 15
Last edited by Kent on Sep 26, 2014 12:42 am, edited 7 times in total.
72 V, (2x36v, 11.5 ah in series) Cellman, HS3540, 18fet Lyen, Jamis Dirtjumper Hardtail. Its streetlegal w license plate, inspection sticker.

Only by setting an example of good road manners and public courtesy can we convince the general public to take the electric bike seriously as a transportation option. Obey traffic laws!

My build: https://endless-sphere.com/forums/viewto ... =6&t=45706
Going legal: https://endless-sphere.com/forums/viewto ... =3&t=49390

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Re: Front Mounted Case with LED Light-PHOTOS!

Post by The fingers » Nov 17, 2012 8:55 pm

Should get additional respect with that. 8)
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Re: Front Mounted Case with LED Light-PHOTOS!

Post by iovaykind » Nov 17, 2012 11:51 pm

Looks good. would get mistaken for a motorbike for sure now, at least at nighttime

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Kent
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Re: Front Mounted Case on Rubber Mounts with LED Light-PHOTO

Post by Kent » Nov 18, 2012 11:25 am

Thanks for the kind words. I guess if its too bright, and cars start flashing their lights at me, the poor dears, then I could filter the brightness by putting a pice of clear plastic over it although i hate to.
72 V, (2x36v, 11.5 ah in series) Cellman, HS3540, 18fet Lyen, Jamis Dirtjumper Hardtail. Its streetlegal w license plate, inspection sticker.

Only by setting an example of good road manners and public courtesy can we convince the general public to take the electric bike seriously as a transportation option. Obey traffic laws!

My build: https://endless-sphere.com/forums/viewto ... =6&t=45706
Going legal: https://endless-sphere.com/forums/viewto ... =3&t=49390

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Re: Front Mounted Case on Rubber Mounts with LED Light-PHOTO

Post by ohzee » Nov 18, 2012 11:50 am

I think it looks great nice work.. very clean looking.

It's funny riding on my bike at dusk going by a motorcycle and him giving you the cool guys hand wave.

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Kent
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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by Kent » Nov 19, 2012 5:45 pm

Now for the second battery. Here is a comparison shot of the two batteries together. Both 36 volt, 11.5 ah. The square brick went in the front rack, the flat one I mounted on the top tube in front of the seat.
Batterys together.jpg
Same capacity-note how the flat one can take up alot less height
Batterys together.jpg (52.78 KiB) Viewed 2112 times
I got the flat one specifically to mount on the top rail in front of the seat. I wanted to keep the rear rack free for cargo and also to better distribute the weight. This way it is equally spread out front/middle/rear wheel. The bike handles well and doesn't wag its tail. Anyway, someone on here gave me the idea (many thanks!) for taking a standard seat tube mount, and re-welding it so it would face front. Seemed like a great idea so first step was making a pattern:
Cardboard Pattern.jpg
Scribe the profile onto cardboard
Cardboard Pattern.jpg (88.27 KiB) Viewed 2112 times
Then using the pattern to trace onto alum plate, cut it out, and finally welded onto the reversed rack:
Middle rack fabricated.jpg
It slips over the seat tube and rests on the top rail-the cutout pattern keeps it from moving.
Middle rack fabricated.jpg (56.34 KiB) Viewed 2112 times

On it goes.
Jamis battery rack mounted.jpg
I left a bit of space under for the controller but it didn't fit!
Jamis battery rack mounted.jpg (102.83 KiB) Viewed 2112 times
A left over bag from my first e-bay kit and some straps:
Bag mounted.jpg
It fits nice between the knees
Bag mounted.jpg (143.4 KiB) Viewed 2112 times
A 2 into 1 "Y" harness before the contoller completes the set up. Yup, I found the diodes weren't necessary as the packs are the same chemistry and I am able to isolate them and charge them separately. All the electrics and the dc/dc converter run off the front pack which is isolated with the on/off key so i don't get the 72 v rush on the controller first thing.

Well, the last stage on my build is a rear 19" moped rim with 2.50 tire from JRH, and a front DMR 24" 20mm wheel with a 2.35 Big Apple from Chain Reaction Cycles.

Many thanks-too numerous to mention-to the many here on ES who have inspired me and given me much needed advice along the way. Theres no beating doing it yourself-for yourself! I see now how so many jump right into another build.
72 V, (2x36v, 11.5 ah in series) Cellman, HS3540, 18fet Lyen, Jamis Dirtjumper Hardtail. Its streetlegal w license plate, inspection sticker.

Only by setting an example of good road manners and public courtesy can we convince the general public to take the electric bike seriously as a transportation option. Obey traffic laws!

My build: https://endless-sphere.com/forums/viewto ... =6&t=45706
Going legal: https://endless-sphere.com/forums/viewto ... =3&t=49390

potatorage
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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by potatorage » Nov 20, 2012 1:05 am

What are you using for turn signals and the front amber lights?

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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by Kent » Nov 20, 2012 6:13 pm

The front amber running lights are cheap Walmart LED's that are like $8 each. Two screw holes in the (plastic) mounting base. I like these cause they take no power and you can see them from the side.

The turn signals I bought as a kit of four with brackets meant to be mounted on a bike. A bit pricey, you could create your own by hunting down parts. The key is the turn signal switch and the flasher which is a standard 12 v universal type. But they do give you a wiring diagram to hook it all up: http://www.heeters.com
turn signal light cluster.jpg
turn signal light cluster.jpg (48.28 KiB) Viewed 2056 times
For the rear turn signals, I skipped the two in the kit and instead hooked up this which has tail/breaklight and turn signals in a nice compact package. Very affordable. Watch out for your grounds on all this stuff, though, as some of the lights have individual grounds, and some are automotive style that assume a chassis ground.
Tail light.jpg
Tail light.jpg (67 KiB) Viewed 2056 times
A very handy little fella which I found useful when tracing circuits and hooking stuff up. A tiny 12 volt, 5ah battery from the local battery supply. Charge it up with a regular auto charger.
Tiny battery.jpg
Tiny battery.jpg (96.57 KiB) Viewed 2056 times
And finally, what gave me the most grief about wiring was dealing with the tiny , small guage diameter wire with all this stuff. 24 and 26 gauge. Ug! :evil: Strip it a little too deep and take out two strands and you've blown it! So after many tries with my $5 flea market special, I broke down and bought this. It made all the difference! :D
wire cutters.jpg
$15 at the local hardware store. Also crimps.
wire cutters.jpg (109.18 KiB) Viewed 2056 times
72 V, (2x36v, 11.5 ah in series) Cellman, HS3540, 18fet Lyen, Jamis Dirtjumper Hardtail. Its streetlegal w license plate, inspection sticker.

Only by setting an example of good road manners and public courtesy can we convince the general public to take the electric bike seriously as a transportation option. Obey traffic laws!

My build: https://endless-sphere.com/forums/viewto ... =6&t=45706
Going legal: https://endless-sphere.com/forums/viewto ... =3&t=49390

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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by ohzee » Nov 20, 2012 6:58 pm

I bought a set of those heeters turn signals also. Even got the guy to let me pay via paypal.

Looking good bud. Nice welding work on that reverse rack battery mount very creative.

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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by Kent » Nov 20, 2012 7:40 pm

Thanks Ohzee but I had the welding done at the local welding shop. I'm just not equipped. But back in the day, I had fun gas welding alum.
72 V, (2x36v, 11.5 ah in series) Cellman, HS3540, 18fet Lyen, Jamis Dirtjumper Hardtail. Its streetlegal w license plate, inspection sticker.

Only by setting an example of good road manners and public courtesy can we convince the general public to take the electric bike seriously as a transportation option. Obey traffic laws!

My build: https://endless-sphere.com/forums/viewto ... =6&t=45706
Going legal: https://endless-sphere.com/forums/viewto ... =3&t=49390

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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by oatnet » Dec 11, 2012 6:22 pm

Wow, just came across this build, you did some great stuff with it, good job. I think that is the same pelican I used on my A-Line build, the lights you put on it disguise its purpose even better. I've got to take a look at the turn signal kit, I've been thinking about that a lot lately.

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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by teklektik » Dec 11, 2012 7:01 pm

oatnet wrote:I've got to take a look at the turn signal kit, I've been thinking about that a lot lately.
Seriously good move - I wouldn't go out on the road without them. Beyond cluing in the autos to biker intentions, it actually seems to elicit quite a bit of courtesy from them - I regularly have cars stop and wave me through turns... :D
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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by The fingers » Dec 11, 2012 9:08 pm

The more lights, reflectors, flashers and bright green attire I add to my rig; the more close calls I have commuting.
I'm about ready to ditch all the safety stuff, go with a wonky Wal-mart incandescant handlebar headlight and only one rear red reflector to return to the years when I could commute unmolested. :twisted:
Black Schwinn High Sierra
Blue Schwinn Cruiser 5
Blue Schwinn High Plains
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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by Kent » Dec 11, 2012 9:54 pm

[quote="The fingers"]
"The more lights, reflectors, flashers and bright green attire I add to my rig; the more close calls I have commuting."

Maybe you over did it Bud and theyre too busy gawking.

I have found too that if I wait patiently at a light, waiting for my turn with the turn signal flashers on, people give me alot of respect and many give me a "go ahead" friendly wave. It also lets them know wtf your doing with a bike in the middle of an intersection... :D
72 V, (2x36v, 11.5 ah in series) Cellman, HS3540, 18fet Lyen, Jamis Dirtjumper Hardtail. Its streetlegal w license plate, inspection sticker.

Only by setting an example of good road manners and public courtesy can we convince the general public to take the electric bike seriously as a transportation option. Obey traffic laws!

My build: https://endless-sphere.com/forums/viewto ... =6&t=45706
Going legal: https://endless-sphere.com/forums/viewto ... =3&t=49390

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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by chisixer6 » Dec 17, 2012 5:30 am

Kent;

I loved your ideal of reversing the mount on the rear rack for use in front of the seat post. I don't weld alumium, so I'll have to come up with another way. thought about cutting the tube and sleeve it and exposey or rivet on over the joint.

In the picture of the universal turn signal is the handlebar switch shown? I am going to check my local Pep boys to see if they have kit.

thanks a lot

Jerry
Motobecane ..bafang front driver.. 42v
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convert my CLWB recumbent to a front bafung@48v..ongoing

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Re: Front Mounted Case/Rubber Mounts/Mid Mnt w LED Light-PHO

Post by Kent » Dec 17, 2012 10:21 am

chisixer6 wrote:Kent;

I loved your ideal of reversing the mount on the rear rack for use in front of the seat post. I don't weld alumium, so I'll have to come up with another way. thought about cutting the tube and sleeve it and exposey or rivet on over the joint.

In the picture of the universal turn signal is the handlebar switch shown? I am going to check my local Pep boys to see if they have kit.

thanks a lot

Jerry

Jerry, the switch in the kit is on the photo, it is the light colored (silver) object in the middle on the left hand side. It clamps on standard 7/8" od handlebars. If you have beefy mtn bike bars, you may have to make a bracket for it. If you figure all the time and effort of hunting down all the parts, and mounting brackets for the lights, i think it is a good deal unless you can source it all locally.
72 V, (2x36v, 11.5 ah in series) Cellman, HS3540, 18fet Lyen, Jamis Dirtjumper Hardtail. Its streetlegal w license plate, inspection sticker.

Only by setting an example of good road manners and public courtesy can we convince the general public to take the electric bike seriously as a transportation option. Obey traffic laws!

My build: https://endless-sphere.com/forums/viewto ... =6&t=45706
Going legal: https://endless-sphere.com/forums/viewto ... =3&t=49390

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