Just another awesome commuter e-bike: rear hub BPM, LiPo

Show off your E-bike creation here.
User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Jun 09, 2013 4:06 am

It's alive!!

Firstly, many thanks to Kabbage, Kepler, Ben Moore, Dogman, Adrian_sm, Spinningmagnets, Andyshirley and others for all invaluable advice I've received. Here is the finished product:

Image

Image Image Image

So the intention was to build a reliable commuter which would pass for a normal pushbike at first glance. The main bits are:
- 2012 Giant Cypress DX hybrid bike (front suspension removed)
- Schwable Marathon Plus 35mm puncture proof (fingers crossed!) rear tyre
- Kool Stop brake pads
- BPM 36V500W rear hub motor
- Ben Moore "little monster" controller, limited to 30A
- Zippy LiPo 44v 4Ah (times 2 packs, the other goes in my backpack for the ride home)
- iCharger 106B (with paraboard to charge all 4 batteries at once)

Thanks to the incredible explosive power of LiPo, unassisted it rides quite similar to pre-conversion. But then twisting the throttle gives it a very nice boost indeed! Personally, I think the conversion is quite discreet, in fact a few friends had no idea until I admitted its "little secret"!

Total cost for the conversion was AU$1200, and it's been worth every cent. E-bikes are an absolute game-changer for urban transportation, and I'm totally stoked with how mine has turned out! :D :D
Last edited by headwind on Jan 27, 2014 1:56 am, edited 1 time in total.
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

User avatar
adrian_sm
100 MW
100 MW
Posts: 2643
Joined: Feb 23, 2009 12:54 am
Location: Melbourne, Australia
Contact:

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by adrian_sm » Jun 09, 2013 4:35 am

8) Very clean.

Did you managed to cram your batteries into that little saddle bag?
Build #1 ~28kg ~ 700w Avanti Hardtail Crystalyte 408, 48V10Ah Headway. ~5500 kms to date. (retired)
Build #2 ~30kg ~2000w Giant AC Dually Crystalyte 408, 48V10Ah Headway + 6s10Ah LiPo = 70V. ~15000 kms to date [SOLD]
Build #3 ~13kg ~2000w Commuter Booster <1kg Friction Drive in Beta testing (www.commuterbooster.com)
Build #??? ~21kg ~1500w Adrian's Bafang BPM Hardtail MTB Bafang BPM code12, 15s LiPo, ~40kph, ~30kms

User avatar
spinningmagnets
100 GW
100 GW
Posts: 10721
Joined: Dec 21, 2007 10:27 pm
Location: Ft Riley, NE Kansas

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by spinningmagnets » Jun 09, 2013 6:23 am

What...no cup holder? (and he calls himself a serious commuter...). And I don't see ANY duct tape (:throws hands up and scowls:)...these new kids...I...I just don't know what to think anymore.

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Jun 09, 2013 8:55 pm

adrian_sm wrote:8) Very clean.

Did you managed to cram your batteries into that little saddle bag?
Yep, there's 2 Zippy batteries snugly sitting in there without any room to bash around, it worked out really well. The other 2 batteries go in my backpack to swap over for the ride home.
spinningmagnets wrote:What...no cup holder? (and he calls himself a serious commuter...). And I don't see ANY duct tape (:throws hands up and scowls:)...these new kids...I...I just don't know what to think anymore.
:lol:
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

User avatar
chas58
10 kW
10 kW
Posts: 814
Joined: Mar 19, 2013 4:05 pm
Location: Detroit, Michigan, USA

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by chas58 » Jun 10, 2013 11:45 am

very, very nice!

post picts of the batteries in your bag/
25^3 bike: 25 lbs, 25 mph, 25 mile range.
Road and Mountain Bike Cute Q100 builds:
https://endless-sphere.com/forums/viewto ... =3&t=49691

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

battery bag

Post by headwind » Jun 14, 2013 5:37 am

Image Image
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

User avatar
Kepler
1 GW
1 GW
Posts: 3070
Joined: Nov 08, 2009 9:22 pm
Location: Eastern suburbs Melbourne Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by Kepler » Jun 14, 2013 6:13 am

Nice job Headwind. Very stealth install. Just make sure you pay good attention to waterproofing the controller the best you can with it in that position. :)
Current Rides

Lightest true ebike on the planet: ON ROAD https://endless-sphere.com/forums/viewt ... =6&t=74269
eBoost on facebook: http://www.facebook.com/pages/Eboost/200306283342024/
75 Volt 6 kW FUTR Beta 29'er: OFF ROAD

User avatar
grindz145
1 GW
1 GW
Posts: 3316
Joined: Apr 07, 2009 12:10 pm
Location: Rochester NY
Contact:

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by grindz145 » Jun 14, 2013 8:11 am

Super-clean very nice!

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Jun 18, 2013 10:25 pm

Kepler wrote:Nice job Headwind. Very stealth install. Just make sure you pay good attention to waterproofing the controller the best you can with it in that position. :)
Thanks mate. You inspired me to put some LiPos under my bum, and I haven't looked back :)

Ben sealed up the controller nicely, I'll keep an eye on it though.
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Jan 27, 2014 2:12 am

Speaking of waterproofing, I've just switched from the makeshift "old inner tube held in place with cables ties" sheath for the wiring connectors to some proper waterproof heatshrink. The inner tube never leaked, but I thought I'd give this a try, and it does look a bit neater.
Image

This heatshrink has glue inside, to create a seal at each end which keeps the water out. Hopefully this glue won't leave a mess if I even need to remove it to access the connectors. Fingers crossed!
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

majornelson
100 W
100 W
Posts: 275
Joined: Jun 29, 2013 8:33 pm
Location: Bethesda, MD

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by majornelson » Jan 28, 2014 6:22 pm

Nice! How is the controller holding up?
Trek DS 8.4, MAC 8T, 48v
Brooklyn Cruiser Q100 Light Commuter Build
https://endless-sphere.com/forums/viewto ... 9&p=794208
1984 Schwinn Supper Sport Conversion
https://endless-sphere.com/forums/viewt ... =3&t=84433

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Jan 28, 2014 9:28 pm

majornelson wrote:Nice! How is the controller holding up?
Yeah, it's been fine. Hasn't copped a hit yet (even though it's close to the road you'd have to be very unlucky for something to collide with it) and seems to keep the water out fine.
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

User avatar
Xanda2260
1 kW
1 kW
Posts: 330
Joined: Mar 11, 2011 4:05 pm
Location: Lowestoft, UK

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by Xanda2260 » Jan 30, 2014 3:59 pm

This is awesome! Exactly what I want to build. May I ask where I can get one of these motors?
The White Warrior - https://endless-sphere.com/forums/viewto ... =6&t=33918
Homebuilt 40mph+ tadpole!

User avatar
Samd
1.21 GW
1.21 GW
Posts: 3829
Joined: Jun 28, 2011 11:08 pm
Location: Ballarat, AU
Contact:

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by Samd » Jan 30, 2014 4:21 pm

Nice work!
http://ballaratebikes.com/

ImageImageImage
"Knowledge is knowing that a tomato is a fruit. Wisdom is knowing that a 165mm rear shock can't deliver 220mm of rear swingarm travel." - Oprah Winfrey.

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Jan 30, 2014 5:46 pm

Xanda2260 wrote:This is awesome! Exactly what I want to build. May I ask where I can get one of these motors?
Thanks!

I got the Bafang from a local guy. Sorry, I don't know any UK suppliers, but they're a big brand so it shouldn't be too hard.
Last edited by headwind on Mar 09, 2014 7:29 pm, edited 1 time in total.
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

User avatar
Xanda2260
1 kW
1 kW
Posts: 330
Joined: Mar 11, 2011 4:05 pm
Location: Lowestoft, UK

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by Xanda2260 » Feb 02, 2014 1:19 am

headwind wrote:
Xanda2260 wrote:This is awesome! Exactly what I want to build. May I ask where I can get one of these motors?
Thanks!

I got the Bafang from a local guy. Sorry, I don't know any UK suppliers, but they're a bit brand so it shouldn't be too hard.
Thanks anyway, I'll have to hunt around.
Fabulous work.
One more question, is that heatshrunk section near your derailleur your controller? It's tiny!
The White Warrior - https://endless-sphere.com/forums/viewto ... =6&t=33918
Homebuilt 40mph+ tadpole!

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Feb 02, 2014 8:11 pm

Xanda2260 wrote:One more question, is that heatshrunk section near your derailleur your controller? It's tiny!
Nope, the controller is under the bottom bracket (see the last pic in the first post).
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Mar 09, 2014 7:36 pm

Update on the waterproof heatshrink:
headwind wrote:This heatshrink has glue inside, to create a seal at each end which keeps the water out. Hopefully this glue won't leave a mess if I even need to remove it to access the connectors. Fingers crossed!
All good. Yay! I've pulled it apart (so the wheel can be rebuilt with stronger spokes) and it came off fine without leaving any mess.

Here's a link, in case anyone is interested: http://www.jaycar.com.au/productView.asp?ID=WH5643
Last edited by headwind on Jul 17, 2016 1:21 am, edited 1 time in total.
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

User avatar
Supertux1
100 W
100 W
Posts: 184
Joined: Mar 18, 2012 11:24 am
Location: Wisconsin, USA

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by Supertux1 » Mar 10, 2014 1:31 pm

What spokes are you going to use? I recommend Sapim Strong Single Butted with 2.3mm ends.

www.wheelbuilder.com has them, but they are a little expensive.
My Commuter/Cargo eBike (MAC 10T): https://endless-sphere.com/forums/viewto ... =6&t=51147
My Off-Road eBike (Bafang BBS02 '750W'): https://endless-sphere.com/forums/viewto ... =6&t=61721

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Mar 10, 2014 5:36 pm

Thanks for the tip.

I'll be using the spokes that the local bike shop recommended, the only thing I know about them is that they're single butted.
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo


User avatar
motomech
100 MW
100 MW
Posts: 2880
Joined: Sep 11, 2010 12:21 am
Location: Tucson Az.

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by motomech » Jun 24, 2014 11:00 pm

A little food for thought;
For the last year I did much what you are doing. I ran 12S\5Ah and when I hit the LVC(or I knew they were low), I would swap-out the two spent bricks for a fresh pair I carried elsewhere.
But recently, I added two more to the system for 12S\10Ah and it is all-around better. Aside from not having to fiddle with batteries and connectors, the motor runs smoother and there is less sag(admitedly, not much sag with Lipo).
Also, the cells hold their balance better, probably due to not discharging as low. For the last 10 cycles, I haven't had to balance at all.
I understand this complicates the stealth a bit, but I doubt anyone would notice another small bag.
You could wire up 12S\10Ah temp as a test and see if you notice a big difference like I did to see if it would be worth it.
Motomech

'03 Rocky Mountain Edge 2WD 260 Q100H frt and Ezee V1 rear 2 Elifebike 20A & 25A 9-FET controllers 12S/20Ah Multistar Lipo rear 5Ah Turnigy frt Luna Cyclops Extra lite Alex 24DM rims, 2.4 Holly Rollers run ghetto tubeless. 25 mph. Mean Well HLG-320H-48A
https://endless-sphere.com/forums/viewt ... =3&t=83430
'07 GT Idive 4 4.0, Q100C 201 12S LiPoly elifebike 9-FET 17A controller. 20 MPH.
https://endless-sphere.com/forums/viewt ... 8#p1237928

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Jun 25, 2014 12:33 am

Thanks for the tip. Yeah, running 10Ah would be a more efficient use of batteries, but there are a couple of practical reasons favouring swapping the packs over. One day I might try strapping extra packs to the bike.

Recently BenMoore showed me a build with the 18650 cells. Wow, they're getting compact and lightweight. Perhaps one day I'll switch over to that. Exciting times!
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

User avatar
headwind
10 W
10 W
Posts: 75
Joined: Mar 27, 2013 6:19 pm
Location: Australia

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by headwind » Nov 23, 2014 6:30 am

The axle in the Bafang motor has snapped :cry:

It lasted 18 months @ approx 70km per week. I can post some photos if anyone is interested, but it's a bit hard to work out what's going on without wiggling it around. Anyway, hopefully it doesn't take long to get the spare motor up and running.

Some general observations after using the bike for 18 months:
- I've been through a few LiPo packs, mainly thanks to occasional brain farts from me. But when a friend recently thought he'd killed his $500+ pack of 18650 cells, I was thankful that my packs are only about $50 each to replace
- Unfortunately the controller I bought off a local guy doesn't have any LVC settings which are useful for LiPo. A higher LVC would have probably saved a couple of my packs.
- Keeping the rear wheel in true is a challenge. The bike shop says it's a good rim and the spokes are strong, so they don't think there's anything else that can be done
- It's still a brilliant form of transport. I can't wait until it's repaired and I'm back in the seat.
Hybrid commuter: BPM 36V500W rear hub motor, 12S 8Ah LiPo

Marc S.
100 W
100 W
Posts: 207
Joined: Jul 04, 2012 12:23 pm
Location: Hamburg, Germany
Contact:

Re: Just another awesome commuter e-bike: rear hub BPM, LiPo

Post by Marc S. » Nov 23, 2014 7:36 am

My BPM2 came with thick 3mm spokes in a 26" rim. I've never managed to keep that wheel straight for more than 50km and had to rebuild the wheel with new spokes and new rim. That new wheel lasted 4,000km without problems till I totalled the rim on a hidden curb under snow.

Since then I've build a dozen wheels and learned a thing or two:
-use 2mm spokes! I use Sapim Leader spokes even with 3kW direct drive hub motor and never had a broken spoke in any my wheels yet (>26,000km).
-deburr the spoke nipple holes of your rim.

Post Reply