Yet another BBS02 build, BeOne Nirvana 2.0

Show off your E-bike creation here.
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Overclocker   10 kW

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Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Oct 03 2016 10:44am

So I snagged a NOS new old-stock BeOne Nirvana f/s frame in the correct size (for me, 19"), and has ample triangle space, so I figured why not turn it into another ebike :twisted:

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BBS02 2016 production w/ upgraded FETs:

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BBS02 custom settings. 22A limit to avoid heat issues. PAS0 and PAS1 set to the same 1-1. The reason for this is that since PAS1 is the bootup default I want my BBS02 to startup w/ PAS disabled i.e. to avoid accidentally throwing me off a cliff

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Battery is Sanyo NCR18650GA 3500mah. 13s4p. No BMS, will simply have external balance port for occasional balancing. BBS02 set to 38V LVC which is just about right for 13s when using these NCA cells w/ 2.5V end voltage. To be charged using a DC-DC boost module:

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Details of boost module charger here: https://endless-sphere.com/forums/viewt ... 14&t=82731


Build in progress...

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Oct 06 2016 1:17am

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slow progress...

kapton tape between cells. bonded w/ neutral-cure black silicone. donut insulators on positive end

7mm x 0.15mm pure nickel welded w/ JP Welder

will do parallel connections next...

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Oct 15 2016 12:13pm

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instead of doing multi-layer nickel at the pack + & - i prefer doing this. 12ga stranded copper for good current distribution, w/ pre-attached nickel tabs, then finally welded onto the cells
Last edited by Overclocker on Oct 25 2016 7:41am, edited 1 time in total.

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Oct 20 2016 12:30pm

the C695 display doesn't show voltage, it only has a bar which doesn't calibrate with the LVC values that you've actually programmed into the controller :roll:

so a voltage display is needed. i selected this one:

https://www.aliexpress.com/item/A96-Fre ... 78092.html

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see youtube link for PDF documentation:



6.94mA draw w/ backlight:

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0.13mA draw, backlight off, LCD active:

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Nov 07 2016 11:16am

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ran it down to LVC, which happened 100m from my house. i actually wouldn't mind pedalling this because it's so lightweight


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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Feb 19 2017 2:49am

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just did a full discharge test of this 13s4p Sanyo GA pack using this nichrome wire contraption. 615Wh. shall test again a year from now to see capacity loss

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » May 27 2017 12:11am

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finally finished the battery box. the cells are bonded to the aluminum shell w/ thermally-conductive silicone

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by tln » May 27 2017 10:37am

Awesome build! Is there a story behind the battery box side covers?

Looks lightweight, whats the final weight (without mud :) )

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » May 28 2017 3:11am

tln wrote:Awesome build! Is there a story behind the battery box side covers?

Looks lightweight, whats the final weight (without mud :) )
oh the side cover graphic? just my lame attempt at emulating the paint job on the bike frame :) while hoping that it would make the battery pack look smaller than it really is. TBH i'm not too happy w/ it :roll:

final weight? no idea but yes it's pretty light compared to my GNG mid-drive bike

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Jun 18 2017 10:27am

IMG_20170618_181249 (Medium).jpg
3k km
IMG_20170618_181249 (Medium).jpg (169.06 KiB) Viewed 2439 times
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it's been a flawless 3000 kms for the bbs02

i also added a handlebar-mounted voltmeter

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Apr 15 2018 7:49am

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same 6.8ohm load

i'm still getting 95% of original capacity after 14 months and over 4000km

new X-fusion rear shock, and testing a different fork:

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Lyo » May 23 2018 11:45am

Looks really neat - how far can you go on a full charge?

So is that right the BBS02 would be the best option for a full suspension; lightweight e-bike, floating typ of e-bike
in comparison to all the hub-drive bikes out there?

I really want to get an e-bike or build one myself; I am living in Germany therefore many bikes and parts I don't want to order from the US too much of a hassle

Thanks for sharing bro!

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » May 24 2018 9:10am

Lyo wrote:
May 23 2018 11:45am
Looks really neat - how far can you go on a full charge?

So is that right the BBS02 would be the best option for a full suspension; lightweight e-bike, floating typ of e-bike
in comparison to all the hub-drive bikes out there?

I really want to get an e-bike or build one myself; I am living in Germany therefore many bikes and parts I don't want to order from the US too much of a hassle

Thanks for sharing bro!

hi. i have a post about range (w/ pedalling) earlier on this thread

yeah the BBS02 is a great choice for MTB use, but it can be difficult finding a compatible frame. you need something w/ a straight downtube, and you don't want suspension parts near the BB area. on top of that you want a large space in the triangle for the battery pack

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Lyo » May 25 2018 10:00am

60KMs wow rock solid
thanks for your advice!

that would be my kinda e-bike :D

then I firstly need to find a good price/quality BBS02 Kit, and a battery pack - would be good to get it from Germany;
inexpensive shipping and no import taxes

I actually just recently started working in a Bicycle Work-Shop here in the Allgäu, repairing bikes and e-bikes.
Unfortunately they are just selling the 'legal' kinda e-bikes there which are pretty poor at 25Kmh max speed here in Germany

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Re: Yet another BBS02 build, BeOne Nirvana 2.0

Post by Overclocker » Jun 16 2019 11:28am

feb2017.jpg
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jun2019.jpg
jun2019.jpg (49.33 KiB) Viewed 659 times
here's something for you Sanyo GA haters :lol:

i tested the capacity of this pack when b-new, then 2 more times in 14 month intervals

no capacity loss between april 2018 and june 2019 8)

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