Rutiger Giant build - Brisbane

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Rutiger   100 W

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Location: Brisbane, Australia

Re: Rutiger Giant build - Brisbane

Post by Rutiger » Mar 21 2014 5:54pm

Still haven't made any solid plans. How's your mate going with yours?
I found a site that was selling very simple torque arms that were just a straight piece of steel with one hole for the axle and one longer slot/hole for a bolt.
It will be too much effort to design and have something custom made.

I have another issue, I need to find an alternative for one of the spacers to go between the rear disc brake and the motor. I should have ordered one from em3ev, but mis-understood what it was for. I thought I could get away with not having one by switching to a 7 speed freewheel.

Nips   1 mW

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Re: Rutiger Giant build - Brisbane

Post by Nips » Mar 21 2014 6:37pm

We should meet up. I bought one and didn't need it in the end.

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » Mar 21 2014 6:46pm

What type did you get?
How much do you want for it?

I don't get back from Groote Eylandt until Wednesday.

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newb   100 W

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Re: Rutiger Giant build - Brisbane

Post by newb » Mar 21 2014 7:05pm

Rutiger wrote:I need to find an alternative for one of the spacers to go between the rear disc brake and the motor
I have an extra as well if needed.

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » Mar 21 2014 7:09pm

newb wrote:I have an extra as well if needed.
Hey newb, long time!
I'd love to grab that off you, it would save me heaps of stuffing around.
Just let me know how much you want for it and I'll come grab it some time.

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newb   100 W

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Re: Rutiger Giant build - Brisbane

Post by newb » Mar 21 2014 8:48pm

yes it has and it's nice to see you are making progress on your build, looks good
if i can be so bold to suggest that before deciding who's you want you measure what size you need
mine is a 1 or 2mm "Hope Disc Spacer" and it cost me about $5.00
i'll measure it and let you know what size i have

Nips   1 mW

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Re: Rutiger Giant build - Brisbane

Post by Nips » Mar 21 2014 9:43pm

It's the disc spacer from em3ev. If we meet up you can have it.

Rutiger   100 W

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Location: Brisbane, Australia

Re: Rutiger Giant build - Brisbane

Post by Rutiger » Mar 21 2014 9:47pm

OK, thanks.

I think I'll need 3-4mm unfortunately, but I'll have a closer look and try to measure the gap when I get home.

Rutiger   100 W

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Location: Brisbane, Australia

Re: Rutiger Giant build - Brisbane

Post by Rutiger » Mar 21 2014 10:05pm

Nips wrote:It's the disc spacer from em3ev. If we meet up you can have it.
Ohh, OK. Sorry, I thought you meant a torque arm and newb was talking about a spacer, but you were both talking about spacers.

That spacer from em3ev should be the right size, thank you.

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » Mar 28 2014 6:18am

Got it together the other day and took it for a test ride in between showers. Hopefully will have time to do more work on various bits tomorrow. :D
Image

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » Mar 30 2014 12:30am

Batteries in battery bag on the bike.

Image

Image

Special thanks to Nips for the spacer, it fit perfectly with my disc, screws, and calipers.

Nips   1 mW

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Re: Rutiger Giant build - Brisbane

Post by Nips » Mar 30 2014 1:03am

Looking good. Nice and clean. That bag fits a treat.

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » Mar 30 2014 1:14am

It's a little bit cramped, and it wouldn't fit with the batteries the way I had them packed originally. I had to put the bag on the bike and pack the batteries differently, which means it sticks out a little bit wider than I had hoped.

My legs do touch the bag a bit if I angle them in a little, but for the most part they shouldn't touch.

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » Apr 01 2014 2:33am

I spent the morning looking after my son who was sick and not at school today, while properly testing the charger on some individual bricks. I charged 6 of them up and went for a few short rides to test it out. Everything works nicely, and got over 50kph at one stage, although it was down a hill.

The thumb throttle seems a bit choppy, does anyone else find that with a cell man kit? From em3ev? It might just be a combination of the spring and new plastic causing the mechanism to be a bit stiff to move, in which case, hopefully it gets better. Otherwise I just need to make an effort to be really smooth and careful otherwise I could end up on my arse with a now heavy bike on top of me.

I'm at the Cairns airport waiting for my next flight to Groote Eylandt to work for the next 7 days, but I am hoping to find some scrap steel that I can make torque arms from, and I'm also hoping to have one of the radio comms guys help me solder up some balance lead conversions to take three 4s JST-XH plugs and convert them to two 6s plugs.

If I can manage those things, within a few hours of getting home I'll be able to balance charge the whole battery pack as one, and take it for a big ride! Hoping to get 70km+ out of it.

Oh, and I almost forgot, while I did manage to get the power supplies wired up in series, when I turn the second power supply on, the first one cuts out. I might need to start my own thread for help on that one. I think it might have something to do with earths or something, but I don't understand things enough to play around with that much zappage.

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maramusa   1 W

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Re: Rutiger Giant build - Brisbane

Post by maramusa » Apr 07 2014 3:02am

Build is looking good.
I has a similar setup MAC 8T 48V gets over 50km/hr on the flats

I bagged the JST-XH connectors on my build thread http://endless-sphere.com/forums/viewto ... 68#p839198, I'm not a huge fan of them, too small and finicky.
I used these from Aussie Ebay http://www.ebay.com.au/itm/5x-WIRE-CONN ... OC:AU:3160, as long as you have the crimpers they are dead easy, and not much bigger if you trim the tabs off, and they still lock.
But then many people seems to like the JST-XH

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » Apr 10 2014 5:45am

maramusa wrote:Build is looking good.
I has a similar setup MAC 8T 48V gets over 50km/hr on the flats

I bagged the JST-XH connectors on my build thread http://endless-sphere.com/forums/viewto ... 68#p839198, I'm not a huge fan of them, too small and finicky.
I used these from Aussie Ebay http://www.ebay.com.au/itm/5x-WIRE-CONN ... OC:AU:3160, as long as you have the crimpers they are dead easy, and not much bigger if you trim the tabs off, and they still lock.
But then many people seems to like the JST-XH
Thanks, those plugs look pretty easy.
Mine is all set up with JST-XH plugs now. I spent hours designing and hours soldering together a big lead to convert 12s 6p (of 4s bricks) to fit into 2x6s on the Hyperion 1420 charger, so unless something melts a lot of wires and plugs, like what happened to yours, I won't be changing.

Rutiger   100 W

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Location: Brisbane, Australia

Re: Rutiger Giant build - Brisbane

Post by Rutiger » May 01 2014 5:32am

Must be time for an update!

I spent time, on and off, for several weeks trying to get the cells in my bricks balanced, until I realised that my Hyperion 1420i charger somehow mis-reads the voltage on cell 2 on both A and B connections. So I ended up charging them all up to 90% TCS and letting them balance over 2 days, in 2 parts (I'm using 18 bricks in 12s 6p format for 44v and 30Ah).
Even though the charger said the cells were up to 0.07v out, I checked them with 3 different voltage checker/alarms and after a couple of cycles through the cell voltages they were all within 0.01-0.02v.

I left the pack charged to about 48v overnight (which is probably a bit high), and then got up a little early to put the rack on the bike, pack the bag, and double check everything. While I was getting ready I charged it up to about 49.7v and set off.

Image

The trip was 30.99km and I rode a bit over half of that with a friend who was powered only by his legs.
I kept it in mode 1 (50%) for about 90% of the trip and averaged 25.3kph for 1 hour and 13 minutes.
Believe it or not I used 233.04Wh, which is only 7.5Wh/km! I was amazed and for half the trip thought there must have been something wrong with the CA to say I only used 4.8Ah for 30km. Upon arrival the voltage was 47.8v, still pretty high.

The trip home was not held up by motor-less riders, only a few busy road crossings, traffic lights, and a couple of tighter bike path sections where I was happy to cruise behind someone else for a few minutes before passing them. I pedalled the whole way unless I was just coasting down a hill without throttle. Unfortunately part of the way home my second pole on the front wheel came loose (I think the one the came with the kit from EM3EV is meant for a larger spoke size), so some of the CA readings may be off. It says my max speed was 408kph, so I'm pretty sure at least that one is accurate! :P

Distance: 29.42km
Top speed: 65kph
Average speed: 32.8kph
Moving time: 53m 45s

End Voltage: 45.9v
Ah used: 7.955Ah
Wh used: 369.19
Wh/km: 12.5

I used a lot more battery on the way home because I kept it in mode 2 and 3 for the whole trip, most of the time using mode 3 and keeping it pinned. I still pedalled the whole way and was happy with how my legs felt afterwards as they were still quite fresh. I was surprised again and very happy with how little battery I used for the round trip, leaving enough Ah to easily do another 60km at a moderate pace.

Some GPS data from the ride:
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About 2/3rds of the way home I sat behind another MTB rider for a while, who was cruising along at a reasonable speed, but when I went to overtake I realised he was on an e-bike too! So of course we chatted about our bikes while we cruised along and then swapped bikes for a bit. Turns out he's a [very quiet] ES member, too!

So all in all, an excellent day.

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » May 01 2014 5:40am

Next on the to do list:
work out why my brakes are shit
tighten the head stem bearings, it's a bit wobbly
replace a jst-xh plug I broke off
and work out what I did wrong with the 3x 4s to 2x 6s balance lead (for balancing 4s @ 12s on the hyperion 1420)

After that's done, I'll have a pretty damn sweet set up!

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » May 05 2014 12:54am

Just ordered a set of these: http://www.chainreactioncycles.com/au/e ... -prod80605

Under $75 delivered for front and rear hydraulic brake kit. Can't wait!

Nips   1 mW

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Re: Rutiger Giant build - Brisbane

Post by Nips » Jun 23 2014 1:54am

Hey Rutiger, how's your build going? Have you fitted your brakes and new chain rings yet?

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Scott   100 W

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Re: Rutiger Giant build - Brisbane

Post by Scott » Jun 23 2014 2:28am

Nice bike, I really like those tires!
Rutiger wrote:Got some new bits today.
One of the cell voltage alarms and parallel balancing cables.
Image
Unless you balance charge every single time I would not recommend having those cell checkers always hooked up to your batteries. I have these and they pull all of their power from only the first 2 cells. This brings the pack out of balance by about 0.02v every ride or 20 minutes.
GCinDC had some nice ones he just plugged in monetarily to check the voltage. I'm going to try to find out what they are this week then ill post back.
Trek Liquid 10 9c 48v 10ah, top speed 28.5 mph. 55.2 mph down a steep hill. - sold
Giant DH Team build http://endless-sphere.com/forums/viewto ... =6&t=51106 top speed 70 mph

Rutiger   100 W

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Location: Brisbane, Australia

Re: Rutiger Giant build - Brisbane

Post by Rutiger » Jun 23 2014 4:43am

Scott wrote:Nice bike, I really like those tires!

Unless you balance charge every single time I would not recommend having those cell checkers always hooked up to your batteries. I have these and they pull all of their power from only the first 2 cells. This brings the pack out of balance by about 0.02v every ride or 20 minutes.
GCinDC had some nice ones he just plugged in monetarily to check the voltage. I'm going to try to find out what they are this week then ill post back.
Thanks, the tyres are hookworms. Very comfy and awesome for street riding.

Thanks for letting me know about the cell alarms, too. I haven't been using them while riding.

Rutiger   100 W

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Location: Brisbane, Australia

Re: Rutiger Giant build - Brisbane

Post by Rutiger » Jun 23 2014 5:07am

Nips wrote:Hey Rutiger, how's your build going? Have you fitted your brakes and new chain rings yet?
Hey mate, hope everything is going well at your place. Hope everyone is healthy and well.

I haven't ridden for a while because I have been sick, and now even though I'm OK, I still have a coughing fit with the slightest of exercise, so I'm waiting for that to disappear before riding again.

I did some work on the bike last weekend and a bit of fiddling the other day as well.
Fitted new chain ring (48t), new chain, new hydraulic brakes front and rear, new shifters front and rear and cable outer.
I had the move the front dera... gear shifty thingy up to clear the massive new chain ring and since fitting everything moved it slightly again which helped with smoother and more accurate shifting on the front rings. Everything is now going quite well there, except that the chain rubs in some places if I'm in a crazy gear combination where the chain runs on an angle from the front to rear cogs. Shouldn't be an issue if I change gears properly.

There is however an issue with the shifter controlling the rear... gear shifty thingy. It's a 7 speed shifter on a 7 speed freewheel, but for some reason it misses some of the gears (basically every second one) and doesn't sit properly on all of them. I've got the end screws on the gear shifty thingy adjusted right so that it won't change inside 1 or outside 7 (and fall off the freewheel), but I can't see any other way to adjust it to use all of the gears on the freewheel.

It seems to me that it's pulling too much cable with each click of the lever, but I can't see any way of adjusting that.
These are the shifters: http://www.chainreactioncycles.com/au/e ... -prod41153

I'm wondering if the easiest thing will be to get one of these to go with it? :(
http://www.chainreactioncycles.com/au/e ... -prod41156
I really can't spend any more money on this damn thing.

Nips   1 mW

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Re: Rutiger Giant build - Brisbane

Post by Nips » Jun 23 2014 5:25am

We're doing well thanks mate!

Sounds like it's all coming along well.

That's a SRAM 1:1 actuation shifter. So it won't be compatible with a shimano derailleur for the very reason you said. Basically it moves more cable per gear than a shimano one would. Yes that new derailleur you linked would fix the problem. What is your current rear derailleur?

You might find this useful: http://en.m.wikibooks.org/wiki/Bicycles ... Dimensions

Rutiger   100 W

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Re: Rutiger Giant build - Brisbane

Post by Rutiger » Jun 23 2014 5:42am

Thanks for the link, makes sense why it's doing what it's doing.

I'll just have to get it lined up on a few of the rear cogs and only use those gears. Maybe I can just use two on the back and two in the front to give me enough range to pedal at various speeds.

Thanks again, stay in touch. Should organise a catch up when you have some spare time.

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