Custom eBike Based on Enduro Frame

Show off your E-bike creation here.
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Burntspot   10 mW

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Custom eBike Based on Enduro Frame

Post by Burntspot » Jan 12 2016 3:25pm

Hi everyone, This is my post to follow my Enduro eBike build. I have been working on the bike for the past 2 months and I figure that I am about two months out before completion. Please let me know if you have any questions or would like me to cover a specific portion of the build not documented. Thanks and enjoy!

This is is my Youtube Link:
https://www.youtube.com/user/adminaeg/v ... &flow=grid

Parts/Specs
Enduro eBike Frame (White)
72V 20AH 18650 cells recovered from laptop batteries
60A continuous 120A peak BMS
Cycle Analyst V3
18Fet Controller
Truvativ Hussefelt 60mm MTB Stem
Killah 200mm Dual Crown 26" Fork
Race Face bar and Sniper Grips
DNM Volcano Rear Shock
SRAM AVID DB5
Ashima Airotor Disc Brake 203mm
Wellgo Xpedo Face Off XMX 18AC Pedals
70's Classic Crank
24" 65mm Rims
Crazy Bob Tire
Crytalyte TC4080

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brumbrum   100 kW

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Re: Custom eBike Based on Enduro Frame

Post by brumbrum » Jan 12 2016 5:13pm

Nice quality video clips, and the bike is looking good too. I always found that laptop batteries were quite restrictive due to their poor discharge ratings, but i guess that the newer laptops have better cells.
My NYX and cromotor build
viewtopic.php?f=6&t=74615
My LMX 161 dirt bike build
viewtopic.php?f=6&t=94074

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Sean9002   1 kW

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Re: Custom eBike Based on Enduro Frame

Post by Sean9002 » Jan 12 2016 6:05pm

Did you weld the battery terminals or solder?
OSET 20+ - Custom frame and swingarm, Motorims - 66V
Ruff Cycles Porucho - MXUS 3000w - whitewalls - Gloss black/Pearl blue/copper leaf - custom tanks - bobber saddle
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39inch longboard Dual 50mm, 12s lipo

Lurkin   100 kW

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Re: Custom eBike Based on Enduro Frame

Post by Lurkin » Jan 12 2016 7:12pm

Subscribed.

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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jan 12 2016 10:40pm

brumbrum wrote:Nice quality video clips, and the bike is looking good too. I always found that laptop batteries were quite restrictive due to their poor discharge ratings, but i guess that the newer laptops have better cells.

I tend to agree. I run a 15S Lipo pack on my other Frankenstein bike and I get a real good punch at peak charge but after about 54V (3.6V/cell) the current drops off. Now the 18650 cell have more energy density at a lower amp discharge. I will be building a second pack with new cells. The new LG MJ1 have a 10A rating which will give me 100A at 10P, double at 20P I am considering (http://batterybro.com/blogs/18650-whole ... ew-3500mah). Thanks for the comment. Hope you stick around for the rest of this build and future ones.
Last edited by Burntspot on Jan 13 2016 8:15am, edited 1 time in total.

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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jan 12 2016 10:42pm

Sean9002 wrote:Did you weld the battery terminals or solder?
The pack is welded. Picked up a 220V welder off of eBay. I have received good results from it. Tabs are cut from .8 x .15 nickel strips. Video coming soon showing details of the pack to include soldering poser leads, BMS soldering, and how it is covered.

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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jan 13 2016 7:16am

Battery as it stands today. I will be making small changes, video coming soon.
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Burntspot   10 mW

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Location: South East

Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jan 15 2016 12:51am

Here is the latest video. The pack completion will be broken up into 2-3 videos:


Lurkin   100 kW

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Re: Custom eBike Based on Enduro Frame

Post by Lurkin » Jan 15 2016 3:04pm

It would be great if you could discuss your BMS source, choice, wiring etc. BMS seem to be where most people (including me) are getting stuck. Discussion like this can be used if you are going to show a lot of one process, like lacing up your BMS or glueing together cells, keeps the audience interested with something they want to know about. Great videos!

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Burntspot   10 mW

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Location: South East

Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jan 15 2016 3:45pm

Lurkin wrote:It would be great if you could discuss your BMS source, choice, wiring etc. BMS seem to be where most people (including me) are getting stuck. Discussion like this can be used if you are going to show a lot of one process, like lacing up your BMS or glueing together cells, keeps the audience interested with something they want to know about. Great videos!
Hi Lurkin, I am glad you like the videos. This is my first build and I, like so many others, have used a lot of resources here on ES and Youtube. I found Damian Rene here: https://www.youtube.com/channel/UCPYVGW ... c1LEeB1o7A and actually took his recommendation for the BMS from his videos. Everything that I have is an experimentation. I am not recommending any products and I do not have any long term exposure to any.

Thanks for the input, producing content is new to me as well. Would you prefer a write-up here on ES or would you prefer more product overviews in the videos before the actual build?

Cheers,
Aastan
Last edited by Burntspot on Jan 15 2016 7:11pm, edited 1 time in total.

Lurkin   100 kW

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Re: Custom eBike Based on Enduro Frame

Post by Lurkin » Jan 15 2016 4:10pm

I like write ups because I often don't have time to watch videos. They are also great if I'm away from a decent internet connection. Making threads on here also make it easier to go back and time, reflect on where you started and see the difference in development to where you end up.

The value in a video is being able to demonstrate something of interest which is hard to communicate well in writing. It's harder than it looks ( :lol: ) to make good video content, because if you are really critical of your own content, you'll find you'll end up cutting it in half or less (not having a go, I have had to do the same elsewhere). The more direct and relevant videos are to the 'need' of the viewer, the better the video.

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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Mar 27 2016 3:57pm

This will be the last photos for this pack. I ran into a setback when I shorted the BMS the new one should be here by the end of the week. A new full 72V pack was purchase just incase I run into more issues. If not, the new pack will be put on my second build. One last video will follow as well of the pack then my focus will be on the pack installation with the completion of the frame. Also the front well has zero offset which causes it to rub the fork. I will capture the repair on video as well.
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Lurkin   100 kW

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Re: Custom eBike Based on Enduro Frame

Post by Lurkin » Mar 27 2016 4:34pm

Just curious - did you do testing of the BMS to determine that it will be work as described? I'm intending to make a summary 'how to' thread, but a little lacking on content... :D

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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Mar 27 2016 6:38pm

Lurkin wrote:Just curious - did you do testing of the BMS to determine that it will be work as described? I'm intending to make a summary 'how to' thread, but a little lacking on content... :D
Not of the current BMS because it was defective. Went through two cycles of charge and dis-charge and on the third time charging to full capacity the BMS stopped working. The balance light indicators won't light up anymore. New BMS should be here by Friday and I will go through the testing process again.

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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » May 19 2016 4:52pm

My standard 8.4v headlights before modification.
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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » May 19 2016 4:55pm

Here they are painted black with new 12V led lights added.
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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jun 01 2016 8:27pm

First ride after battery pack completed. Enduro frame 72v with 20ah 18650 pack.
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pucksterpete   1 kW

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Re: Custom eBike Based on Enduro Frame

Post by pucksterpete » Jun 02 2016 2:39am

and the verdict is? any video?
Optim Alp Hardtail with MXUS Motor
20S 2P Turnigy 5.0 Hard Case
Top speed 38mph tops :)
Hyena Special
http://endless-sphere.com/forums/viewto ... 97#p585997
-------
Excelsior/Strong GTS with Cromotor
24S 3P Turnigy 5.0 Hard Case
Top speed so far 53mph
http://endless-sphere.com/forums/viewto ... =6&t=46993

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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jun 06 2016 10:30pm

Everything fit perfectly. Only short coming is the pack of used cells. Only able to deliver 2amps per cell which is 20amp peak accounting for resistance and age. Building new pack of Sanyo 3.5ah 10amp 18650GA cells. That's 100amp peak (20s10p). Suspension is good tires are great for the road. For the price you get Bomber performance for half the price. Will try to get a video in before new pack is finished
Last edited by Burntspot on Jun 23 2016 9:41am, edited 1 time in total.

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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jun 09 2016 7:54pm

Batteries in and tested. A total of 200 Sanyo 18650GA 3.5ah. They all arrived at 3.50v and the capacities look good!
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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jun 22 2016 7:20pm

Last edited by Burntspot on Jun 23 2016 9:39am, edited 2 times in total.

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Quokka   1 kW

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Re: Custom eBike Based on Enduro Frame

Post by Quokka » Jun 23 2016 8:40am

Subd
Qulbix Q76R+ QS205+MaxE

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spinningmagnets   100 GW

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Re: Custom eBike Based on Enduro Frame

Post by spinningmagnets » Jun 23 2016 8:50am

"Nicely done" -Stringer Bell ["The Wire" end of season one]

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Burntspot   10 mW

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Re: Custom eBike Based on Enduro Frame

Post by Burntspot » Jul 19 2016 7:38pm


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E-geezer   100 W

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Re: Custom eBike Based on Enduro Frame

Post by E-geezer » Jul 26 2016 2:26pm

Having crashed into many a top tube over the years, those key placements always makes me cringe a little.... :shock:
The older I get, the faster I was

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