My first victim - Giant OCR with BBS02

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timk
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My first victim - Giant OCR with BBS02

Post by timk » Jul 14, 2016 9:28 pm

Hi guys,

I've been lurking for a while, but I have also been collecting the bits to put together my first electric bike. It's still a work in progress so I am going to use this thread like a build diary. The objective is a reliable and quick road/bikeway commuter to make biking to work a more attractive option! 8)

My first purchase was a used 2008 Giant OCR complete with weathered chain and perishing tyres:

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At first I thought the rims were worn but it is just some surface corrosion, the bike has barely done any mileage. Importantly the frame, brakes, wheels and RD/shifters are all working well. I pretended the bike was a CX bike and took it on some trails near my house to test everything was working as intended, it all seems quite solid. The standard RD-2200 rear derailleur even worked smoothly with a 11-32 cassette!

The next step was to make a cardboard template to ensure the battery pack I intended to buy would fit, a shame both drink holders are no longer usable but looks good otherwise:

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I also checked the distance between the BB shell and the outside of the frame (quite small, so no problems here), and the type of BB shell (68mm English). Everything checks out, time to pull that trigger on the order!

I bought the BBS02 from Paul and his team at EM3EV, my only comment is they had a shipping issue with the battery using TNT but everything was sorted out quickly by them using an alternate carrier at no cost to me. Big thumbs up for service from EM3EV, and their workmanship on the crimping/heatshrink looks great. Here are the fun bits:

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Armed with my $20 Aldi bike toolkit, I started stripping down the bike and removing the crank, the tools held up fine for this step:

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Unfortunately when I went to remove the bottom bracket cup I found the tolerances on the tool weren't good enough and some splines were too fat:

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Fortunately I was able to tidy these up with an angle grinder:

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I have done a test fit of the tool and it engages fine now, but I haven't gotten any further. I'll try to document the rest of the build as I go. I hope you find this build as interesting as I do!

Cheers!

J-2X
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Re: My first victim - Giant OCR with BBS02

Post by J-2X » Jul 14, 2016 9:37 pm

cool! looking forward to seeing more progress pics tim :)

timk
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Re: My first victim - Giant OCR with BBS02

Post by timk » Jul 17, 2016 5:57 am

The tool now worked fine to remove the bottom bracket:

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The shell looks really clean already:

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Here's the next snag, the bracket for the shifter cables gets in the way of the BBS02:

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After a bit of thinking, I came up with the idea of using some cable outer tube and a cable clamp. Here are the clamps I bought:

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Looks promising:

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Bolts up fine:

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Yes! It worked:

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Time will tell if this is a reliable solution, but it looks pretty good to me. I'll probably zip tie the cable outer to the frame at each side with a gentle radius.

Cheers!

cruzin
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Re: My first victim - Giant OCR with BBS02

Post by cruzin » Jul 17, 2016 10:13 am

good luck on your build. i have found that the more detailed and safety orientated you are, the more enjoyment you will get out of your completed project.


nice bike!

timk
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Re: My first victim - Giant OCR with BBS02

Post by timk » Jul 23, 2016 2:34 am

Thanks cruzin, I think I suffer from OCD a bit! :oops:

I now had all the parts and tools available to fit the motor to the BB shell. I had read that the high torque from the motor could dent alloy frames so I picked up some Neoprene rubber to try and reduce the chance of this happening:

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Rubber applied:

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Test fit, the final fit will have the rubber fully compressed between the motor and frame:

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Looks good!

One slight issue I had was the hole on this steel bracket being drilled slightly offset, meaning the fastener wasn't able to be fitted without binding. I drilled the hole 0.5mm larger then nail polished the exposed metal:

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Thanks yet again to my Aldi bike toolkit I had the right tool on hand. I was able to (blue) Loctite then tighten at the same time as holding the motor against the frame fully compressing the rubber:

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All done:

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I then applied Loctite to the two additional bolts and the extra lockring (you can use a standard Shimano Hollowtech II tool) then fitted:

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Here's a pic after I fitted both crankarms and chain:

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It's starting to come together!

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keithmac
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Re: My first victim - Giant OCR with BBS02

Post by keithmac » Jul 23, 2016 7:31 am

Motor looks nice and high up there, well outnof harms way!.

What display have you got?, any pictures of it :wink:.

Rodney64
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Re: My first victim - Giant OCR with BBS02

Post by Rodney64 » Jul 23, 2016 9:29 am

Nice write up. Looking forward to a ride report.

timk
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Re: My first victim - Giant OCR with BBS02

Post by timk » Aug 04, 2016 5:50 am

The next stage of the build was fitting the additional sensors. The kit came with a wheel speed sensor, and as my bike has drop bars I optioned two HWBS (Hidden Wire Brake Sensor) devices.

Here's the wheel speed sensor and magnet fitted, talk about a monster magnet:

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I decided to fit the brake sensors along the bars themselves by peeling back the bar tape a bit:

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No where to be seen, and as an added bonus gives the bars quite an ergo feel:

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I now had to plan where to mount the screen, throttle and controls. I also had to keep room for a headlight and Garmin bike computer. The biggest problem (which I had known all along) was the internal diameter of the throttle and controls (22.2mm) being too small for my drop bars.

Having access to a 3D printer, I designed some parts to mount these accessories.

The first part I designed was a spacer for the DPC-14 display so I could orient the screen on the bracket by 180 degrees. Some Bafang documentation suggests this is possible but on my screen with a charge port, the charge port wires get in the way.

Here are some pics of the screen with the spacer fitted, and with the fasteners replaced with longer ones to retain the same thread engagement:

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You can download the model file from Thingiverse.

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wineboyrider
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Re: My first victim - Giant OCR with BBS02

Post by wineboyrider » Aug 04, 2016 6:01 am

That should be a fast one. What gears do you have on it?
ES IS SAVED! THANK YOU JUSTIN.

timk
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Re: My first victim - Giant OCR with BBS02

Post by timk » Aug 04, 2016 6:09 am

It's gear limited for sure, highest gear is 42/11. That's probably for the best. :lol:

timk
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Re: My first victim - Giant OCR with BBS02

Post by timk » Aug 04, 2016 6:40 am

After about 6 revisions I finally had a workable design for mounting my accessories. I decided to design a mount in two parts that when brought together form a ring around the stem to allow a second "row" of stuff to be mounted.

Here's the final design:

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It is all held together only by the accessories mounted to it, but it seems quite solid. Originally the top and bottom parts were identical, but I had to change to an offset design to mount the light higher. The larger lobe is to accomodate the headlight's mount which is designed for an oversized bar.

Here's everything bolted up and in place, I'm very happy with the result:

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The throttle is easily within reach of my left thumb when not in the drops, and I can safely keep my right hand near the front brake at the same time. I also really like having the Bafang display quite far forward as it makes it always easy to see. The IPS display looks amazing even in direct sunlight:

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I took the bike for a test ride and wasn't able to wipe the grin from my face! Talk about making cycling effortless!

Here's the bike fully completed, although disregard the low seat hight:

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The 42/11-30 gearing seems to work quite well for my intended purpose of using this bike as a commuter.

I have a warning though; I have used the bike four times now and have done about 90km. In the last 10km I noticed a bit of a clicking noise when pedalling, it turns out the lock ring had become slightly lose. This surprised me as I used thread locker and applied the correct amount of torque to the lock ring, I assumed the ones having trouble weren't doing the install correctly. Today I re-tightened the lock ring to "epic tight" and will monitor it.

J-2X
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Re: My first victim - Giant OCR with BBS02

Post by J-2X » Aug 04, 2016 8:26 am

i want a ride :)

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Alan B
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Re: My first victim - Giant OCR with BBS02

Post by Alan B » Aug 04, 2016 9:02 am

Even done right they tend to "bed in" and require one retightening.

The foam spacer also allows the motor to move a tiny bit. If it loosens again consider an epoxy putty spacer that is stiff. Maintenance requires removing the motor periodically so hopefully "epic tight" will still be removable.

timk
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Re: My first victim - Giant OCR with BBS02

Post by timk » Aug 04, 2016 4:33 pm

That's reassuring Alan. Do you know of any recommended maintenance schedule?

timk
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Re: My first victim - Giant OCR with BBS02

Post by timk » Sep 08, 2016 2:10 am

I have almost clicked over 500km now and the lock ring is still intact, and no other issues! I'm very happy with the bike and I'm using it daily for commutes.

I've fitted a rear mudguard but other than that it has just been a matter of cleaning the chain and charging the battery!

dustNbone
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Re: My first victim - Giant OCR with BBS02

Post by dustNbone » Sep 08, 2016 2:26 pm

Nice build, I bet that makes a great commuter. I've been running my BBS02 on my touring bike for almost 4,000km and it's been very solid for me. I highly recommend doing the regrease job at least on the final drive (large nylon gear) side, for me it turned the slight buzz from the BBS02 under load into near silence. I did mine after about 250km, and I think it's nearly due to have it done again. I don't know what effect if any it has on reliability but the ride quality went way up, and it looks like you have all the tools you need to make it a very easy job.

m3lonbr3ad
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Re: My first victim - Giant OCR with BBS02

Post by m3lonbr3ad » Apr 01, 2017 10:09 pm

Looks great! I want to do something similar, but have some questions. I have a Giant OCR and would like to install a BBSHD. I am trying to get some additional input on clearances for installation. In particular, you had to move the rear derailleur cable into a full length housing, but would I likely need to do this with the BBSHD? Or are the dimensions and mounting tolerances different? I cannot seem to locate good information on how exactly the BBSHD or BBS02 mount, other than using high pressure on the bottom bracket. Is there going to be contact with the bottom tube always and that it why you applied your neoprene padding? Is there clearance if you rotate the motor? Is there likelihood that the motor will move after mounting? Do people use loctite or something similar to ensure this doesnt happen?

Additionally, it seems there are different hidden wire brake sensors out now, what do you think of the smaller black ones commonly associated with the following part number: ms-bk-1f

Thanks!

timk
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Re: My first victim - Giant OCR with BBS02

Post by timk » Apr 02, 2017 1:52 am

Thanks melonbr3ad! I don't think you'll be able to get away with not using a cable outer near the BB unfortunately; there's not much clearance at all. Yes the motor is held in place by friction on the sides of the BB housing. You will want the motor to be hard up against the bottom tube or it will twist itself there due to the torque. My setup had to be re-torqued after the initial 100km even with Loctite being used, but after this re-torque it hasn't loosened again.

The hidden wire sensors you mentioned look fine but I don't have first hand experience with them. Mine are working really well!

Here's how my steed looks after over 1,000km of use, it's filthy from the rain:

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Cheers

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