Giant dh team, with custom build frame

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flua73   1 W

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Giant dh team, with custom build frame

Post by flua73 » Jun 06 2014 3:28pm

Has for some time begun on yet another e-bike build. Have liked Giant dh team cycle of its compact rear suspension, but would have room for a lot of battery in the frame. Found a worn / old frame for the right money to cut into parts. My plan is swing arm and rear suspention from team dh bike with an aluminum battery front (stealth fighter style) with room for 15s 5-6s lipo :) , Here are some pictures, hope you like it ..
Flua 73
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donor bike
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my plans
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forgot the camera last weekend, so the frame is next ready now ..

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Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

evolutiongts   10 kW

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Re: Giant dh team, with custom build frame

Post by evolutiongts » Jun 06 2014 3:38pm

Wow
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Kepler   1 GW

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Re: Giant dh team, with custom build frame

Post by Kepler » Jun 06 2014 4:27pm

Fantastic work. Great fabrication skill there. I particularly like the way you flanged the swing arm Assembly to attached to the battery box. Makes the build modular and opens up opportunities to design different front boxes and have them interchangeable. The current front section is quite Bomber like with nice lines and plenty of battery capacity ready for a high powered hub. You could do a second front section designed for say 600Wh of battery that is more compact and streamline suitable for say a geared hub build.

Anyway, very nice build. Subscribed and look forward to seen the bike progress. 8)
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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Jun 06 2014 4:45pm

Thanks "Kepler" I have another e-bike (specialized big hit http://endless-sphere.com/forums/viewto ... 73#p800504) As I use daily 84V 10Ah. The next project is to fabricate a seat post mount..
Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

H.I.M   10 µW

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Re: Giant dh team, with custom build frame

Post by H.I.M » Jun 07 2014 3:10am

Wow. What alloy used for boxes? What brand?

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ridethelightning   1 MW

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Re: Giant dh team, with custom build frame

Post by ridethelightning » Jun 07 2014 4:38am

sweet! :D

cheekybloke   1 kW

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Re: Giant dh team, with custom build frame

Post by cheekybloke » Jun 07 2014 7:22am

very impressed matey,i am just planning the same on type of thing but going mid drive,any chance of the dimensions of the front triangle box?
darren

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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Jun 08 2014 4:17am

H.I.M wrote:Wow. What alloy used for boxes? What brand?


It was aluminum plate that I found at my job, the name is 5083 and the box is 3mm thick. Then the part that the shock absorber is attached against 5mm thick, and reinforced with a threaded stainless steel plate on the inside
Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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madin88   100 MW

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Re: Giant dh team, with custom build frame

Post by madin88 » Jun 08 2014 4:25am

great work. looking forward to see the finished bike :)
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voicecoils   10 MW

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Re: Giant dh team, with custom build frame

Post by voicecoils » Jun 08 2014 4:26am

I think this will be the best Giant DH Team / Comp build yet! Very nice fabrication work.

That was the dream for my DH Team in 2008. I wish I had your welding skills 8)

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izeman   10 GW

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Re: Giant dh team, with custom build frame

Post by izeman » Jun 08 2014 5:18am

5xxx alloy should be heat treated after welding. it becomes very soft. i used 7020 because of that.

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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Jun 08 2014 6:21am

izeman wrote:5xxx alloy should be heat treated after welding. it becomes very soft. i used 7020 because of that.
You're probably right, I'm not as well read on aluminum alloys. from wikipedia

"Alloy 5083 Retains exceptional strength after welding. It has the highest strength of the non-heat treatable alloys"

Flua73
Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Jun 08 2014 6:41am

voicecoils wrote:I think this will be the best Giant DH Team / Comp build yet! Very nice fabrication work.

That was the dream for my DH Team in 2008. I wish I had your welding skills 8)
Thanks man :oops: , I'll do my best. Must read through your building
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Having searched high and low for the bolt and washer / cap. find only bearing kit. Anyone have a tip on where to find it?
Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Jul 03 2014 12:35pm

Work has continued to manufacture the bracket for the seat. Have had some problems getting the design right, but now almost right. Are there more than "Zelena vozila d.o.o." selling cromotor in europe?
flua73
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Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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flua73   1 W

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Re: Giant dh team, with custom build frame....

Post by flua73 » Aug 21 2014 11:59am

some things have arrived at the building, controller Kelly KBL 96251st And cromotor v2, which unfortunately had the rim been destroyed in shipping, dented and warped. damn tiring when this happens :twisted: . Notified to the shipping company and are waiting to hear .. Now for something better has been manufacturing "heavy duty" stainless steel dropout plates. With plenty of space for the engine. Have threaded aluminum plates and inserted stainless v-coil threads. Very happy with the result, very stable :D . Here are some pictures ....
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Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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nicobie   10 MW

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Re: Giant dh team, with custom build frame

Post by nicobie » Aug 21 2014 2:48pm

Very, Very nice.

You do beautiful work.
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May your tote always stay tight and your edge eversharp :wink:

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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Aug 23 2014 8:54am

tried to mount the rear wheel complete, was a little worried that it would be too low with 24 "rims. now it feels fine ..
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Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Aug 30 2014 5:20am

Have bought a couple of second hand hope brakes, front Mono 6 ti and back mini mono with floating rotors. if they stop the bike as good as they are good looking :shock: , I get happy. will be connected to a pair BionX Press Switch for brake cut-off...
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Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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waynebergman   10 kW

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Re: Giant dh team, with custom build frame

Post by waynebergman » Aug 30 2014 12:37pm

flua73, your bike is looking awesome. Way to go. I see you have kept your seat tube angle on the steep side and I am guessing it is so the seat tube is not interrupted by the fabrication you have put together for the battery enclosure. Just an idea for you, if you ever want to put a bit more slackness into that seat tube mast bringing it closer to the stock angles you could go with a dropper seat post. I have a dropper seat post and I would never be with out one now. Its so cool to be able to adjust the saddle height on the fly with the trigger switch on the handle bars. If you had one of these posts you could easily put the regular angle back to seat tube mast and have plenty of room for full up and full down riding heights with out bumping into the battery enclosure. Just a thought and you may be fine with just how it is but to me the seat tube angle looks very steep as it is now.

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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Aug 31 2014 6:19am

waynebergman wrote:flua73, your bike is looking awesome. Way to go. I see you have kept your seat tube angle on the steep side and I am guessing it is so the seat tube is not interrupted by the fabrication you have put together for the battery enclosure. Just an idea for you, if you ever want to put a bit more slackness into that seat tube mast bringing it closer to the stock angles you could go with a dropper seat post. I have a dropper seat post and I would never be with out one now. Its so cool to be able to adjust the saddle height on the fly with the trigger switch on the handle bars. If you had one of these posts you could easily put the regular angle back to seat tube mast and have plenty of room for full up and full down riding heights with out bumping into the battery enclosure. Just a thought and you may be fine with just how it is but to me the seat tube angle looks very steep as it is now.



Hey Wayne Bergman

according to me, it does not angle to the pipe so important just the saddle in the correct position, as you know, goes to the saddle can adjust until you find the right position. We'll see how it feels to drive when I get it going. About dropper seat so I have two buddies who have been using these, maybe they've had bad luck but they have the most messed leaked air (RockShox Reverb), etc. but there are of course the ones that work better. But surely a good thing when it's working as it should. But it would appear that I would have a different seat tube angle, so I made ​​seat tube mount as a removable bracket that is secured by a bolt connection, so nothing is carved in stone .... Thanks for your input
Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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waynebergman   10 kW

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Re: Giant dh team, with custom build frame

Post by waynebergman » Aug 31 2014 2:18pm

flua73, some advantages that I see with the stock seat tube angles (like how the frame originally came from the factory) when it comes to day to day riding is....

1.With moving the saddle height up high when in pedalling mode, the saddle naturally slides rearward behind the BB where you want it to be when pedalling and then when you lower the saddle for riding down steeper sections of trail, the saddle will also move forward as it moves down if you have a slacker angle to your frames seat tube. This forward movement of the saddle when dropping it lower is nice as you can get behind the saddle and your body weight more over the rear wheel when descending steeper sections of trail without having the saddle in your way.

2.It just looks better in my opinion. No body makes a serious down hill bike with steep seat tube angles (that I know of anyways).

Some people set there saddle height once and just leave it there. On DH bikes the guys who shuttle do this and they just leave the saddle super low for rding the steeps and the x-country guys may leave the seat up high because they don't ride steeper downhill sections but to get the most out of an electric pedal assist DH bike I would want to get the benifits of my first two points if I could.

This is just my opinion however and I guess it depends somewhat on your riding style and if you care that the seat tube angle looks steeper than most. I love the bike and look forward to seeing more updates on the fun you will surely have on it.

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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Sep 02 2014 2:11pm

Wayne Bergman
You're probably quite right in your analysis, I feel like I can take a turn back to the "drawing board" :D
Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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flua73   1 W

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Re: Giant dh team, with custom build frame

Post by flua73 » Sep 07 2014 6:35am

Have figured on a new seat post mount this weekend, pretty happy with the result. Now I'm just waiting on the mail man to come with batteries ..
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Giant dh custom alloy frame, cromotor v2, kelly kbl 96251, cycle analyst v3, lipo 24s 4p

my building threads http://endless-sphere.com/forums/viewto ... ustom+fram
Nyx, Adappto Max-e, cromotor 21s/16p :D

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waynebergman   10 kW

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Re: Giant dh team, with custom build frame

Post by waynebergman » Sep 07 2014 10:59am

Wow! Looking good. I hope your battery packs work well for you. I also am running a 24" wheel and it is fine. Of course the fatter the tire you are able to find for that 24" rim the larger its diameter will become as well. I have found the 24" tires are hard to find in most LBS so if you find the right width and diameter that works for you maybe buy a few tires while you are at it before they get really hard to find. I have found some nice 2.30" wide 24' tires for 25 bucks a piece so I bought 4 of them.

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Re: Giant dh team, with custom build frame

Post by litespeed » Sep 07 2014 9:03pm

That looks excellent!

Tom
I'm married so you know I'm no stranger to pain!

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