As most of my exams are over, I had some time to work on the bike.
Pictures tell more than a thousand words:
Testfit of all components on the bike. It is still comfortably light.
Battery is 10 packs of 5Ah 4s hobbyking lipo. This equals a 74V nominal 10Ah battery, and I still have room for 5Ah more or so. But mixing new and old lipo isn't the best idea, so I'll stick to the current battery.
Adaptto will be inside the battery case, because on my previous build, maxing it out with 6KW+ it never even got warm. Although I will have to see about this, because I'm not entirely sure that the higher eRPM won't create more heat in the controller, even when running less power, I'm shooting for about 2-3kw.
Only the right one of the two switches is currently wired as a throttle cutoff, which is very useful when getting off the bike and not wanting it to accidentally leap around or when going slow around town/people.
Maybe I'll use some of the others for the front/back lights later.
I managed to carefully remove the original BBSHD controller from the housing and then soldered a new cable with XT150 connectors for the phase wires. Afterwards I soldered a new wiring harness for the throttle / speed sensor using plugs, so unplugging the throttle and the speed sensor is now easily possible without removing the whole wiring from the bike. Then I mounted the motor to the bike and it fits like a glove! You can't even really see it behind the large chainring. Ground clearance might be a problem, hmm.
I am planning to buy more of these black metal strips from the hardware store which I used for my last build to fix the battery-box to the bike. Then some more sanding, filling, sanding etc. for the box. The most boring part of the whole build. I ordered a shift sensor (GSD from gearsensor.com) with my BBSHD, but I didn't think that the regen/brake cutoff wire on the MINI-E would be used for the external speed sensor... So I basically only have the throttle signal line to work with. The worst thing is I can't even find a wiring diagram for the gearsensor so I could create a circuit for pulling the throttle signal down to ground. This will require some tinkering around, but it's currently not vital to get the bike running, which is what I've been pursuing as top priority. I will have to get a longer chain, the one that's on the bike is way too short for the 42T Lekkie Bling Ring.
At this stage, the bike test-fitted with the motor, controller, throttle, battery and everything else terribly important still weighs less than my last build with only the motor and nothing else mounted! I am pretty excited to ride it soon...
At last, could anyone tell me what kind of sensor this thing is? I suppose it's some kind of hall sensor, but for what? It was included with my BBSHD and I can't find any info on it in the manuals.