8kw Enduro Frame Build

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Yermommy   1 W

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8kw Enduro Frame Build

Post by Yermommy » Apr 08 2018 8:56am

Hi all! I’ll be using this thread to document my 8kw enduro frame build. I’m currently waiting for a few more parts to arrive and I should be able to finish it next weekend. Here’s a list of the parts I’ll be using:
  • White Enduro Frame
  • DNM fork
  • DNM rear shock
  • MXUS 3K Turbo 5T
  • Sabvoton 72v 150a controller
  • 72v 20ah 18650 battery pack, 70a continuous, 100a peak
  • 26” front wheel, 20mm thru axle
  • 20 24” rear wheel
  • 5” rise handle bar
  • Full twist throttle with voltage display and 3 way switch
  • 160 180mm mechanical disc brakes
I’ll try to keep this updated as I build, wire, and program everything!
Attachments
A92B35D3-108D-4CFA-906B-73EBDEDB97A1.jpeg
A92B35D3-108D-4CFA-906B-73EBDEDB97A1.jpeg (230.28 KiB) Viewed 2252 times
Last edited by Yermommy on May 01 2018 7:33pm, edited 1 time in total.

John in CR   100 GW

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Re: 8kw Enduro Frame Build

Post by John in CR » Apr 08 2018 7:16pm

What's the brand and source for your Enduro frame? What is the weight of the frame with swingarm? It looks significantly different than the one I have in some good ways...primarily that it's a monocoque structure instead of square tubing based, and I like that for the space savings. To me tubing just wastes space, and space for batteries is the biggest premium on our ebikes.

ScooterMan101   1 MW

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Joined: Oct 06 2012 4:45pm
Location: South of San Jose, California.

Re: 8kw Enduro Frame Build

Post by ScooterMan101 » Apr 08 2018 8:20pm

Nice ,

Looks like the Frame from Em3ev, did you buy the DNM fork from them ?
yours looks like a gold color coating on the legs , higher price on that fork than what we usually see from a DNM fork ?

That bike is going to be Allot of Fun .
My first conversion ...

https://endless-sphere.com/forums/viewt ... 1#p1077497

It's 2018 already, lets get some real , improved e-bike / e-velomobile / e-motorcycle designs .

Yermommy   1 W

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Posts: 56
Joined: Mar 17 2018 1:18pm

Re: 8kw Enduro Frame Build

Post by Yermommy » Apr 08 2018 9:09pm

John in CR wrote:
Apr 08 2018 7:16pm
What's the brand and source for your Enduro frame? What is the weight of the frame with swingarm? It looks significantly different than the one I have in some good ways...primarily that it's a monocoque structure instead of square tubing based, and I like that for the space savings. To me tubing just wastes space, and space for batteries is the biggest premium on our ebikes.
Believe it or not, I actually got it from Amazon. There's a ton of extra space inside the frame, even with a 20ah battery. Could probably fit a 30ah if I build the next battery myself.

Yermommy   1 W

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Joined: Mar 17 2018 1:18pm

Re: 8kw Enduro Frame Build

Post by Yermommy » Apr 08 2018 9:11pm

ScooterMan101 wrote:
Apr 08 2018 8:20pm
Nice ,

Looks like the Frame from Em3ev, did you buy the DNM fork from them ?
yours looks like a gold color coating on the legs , higher price on that fork than what we usually see from a DNM fork ?

That bike is going to be Allot of Fun .
The frame is from Amazon and the DNM fork is as well. Paid $350 for the fork but I think it had been discounted from $450.

Yermommy   1 W

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Posts: 56
Joined: Mar 17 2018 1:18pm

Re: 8kw Enduro Frame Build

Post by Yermommy » Apr 11 2018 7:00pm

Wheel came in yesterday.

Image
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John in CR   100 GW

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Location: Paradise

Re: 8kw Enduro Frame Build

Post by John in CR » Apr 11 2018 9:24pm

Biggest 20" rim I've ever seen.

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ridethelightning   1 MW

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Re: 8kw Enduro Frame Build

Post by ridethelightning » Apr 12 2018 7:31am

frame steel or aly?
i have worked on a cheap alu version with the square tubing which was light, but did not fill me with high amp confidence..
even the bolt on "torque plates" i diddnt realise, were painted blocks of soft aluminium which chewed just with testing the motor on the stand :shock:

John in CR   100 GW

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Posts: 13522
Joined: May 20 2008 12:58am
Location: Paradise

Re: 8kw Enduro Frame Build

Post by John in CR » Apr 12 2018 7:48am

What's the true weight of the raw frame? The Amazon listing says 23kgs :shock: , which can't be right since the shipping weight was less. That's definitely not the small square tubing based Enduro like sold by em3ev, which has tons of wasted space in the construction. This one looks cavernous inside. What's the interior width?

ScooterMan101   1 MW

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Joined: Oct 06 2012 4:45pm
Location: South of San Jose, California.

Re: 8kw Enduro Frame Build

Post by ScooterMan101 » Apr 12 2018 10:20am

Aluminum Torque Plates ?

What was the version you worked on ?
meaning
Model and from which vendor .



ridethelightning wrote:
Apr 12 2018 7:31am

i have worked on a cheap alu version with the square tubing which was light, but did not fill me with high amp confidence..
even the bolt on "torque plates" i diddnt realise, were painted blocks of soft aluminium which chewed just with testing the motor on the stand :shock:
My first conversion ...

https://endless-sphere.com/forums/viewt ... 1#p1077497

It's 2018 already, lets get some real , improved e-bike / e-velomobile / e-motorcycle designs .

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ridethelightning   1 MW

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Re: 8kw Enduro Frame Build

Post by ridethelightning » Apr 13 2018 7:03am

well u see i diddnt order it, i was working on it for a friend. i think he got it from leli ebikes or other china supplier but definately not em3ev

cheeko   10 mW

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Location: Brisbane AU

Re: 8kw Enduro Frame Build

Post by cheeko » Apr 19 2018 8:15pm

Liking this build might tag along.

I just ordered the MXUS 3k too

Yermommy   1 W

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Joined: Mar 17 2018 1:18pm

Re: 8kw Enduro Frame Build

Post by Yermommy » Apr 23 2018 4:18pm

I hooked up the controller to the battery in order to do the angle testing. All went well, so I installed the tire. Just waiting for my front wheel to be rebuilt, then I'll have basically everything I need. Here's a few more pics of what's changed:

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Yermommy   1 W

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Joined: Mar 17 2018 1:18pm

Re: 8kw Enduro Frame Build

Post by Yermommy » May 01 2018 7:31pm

I mostly finished the build over the last 3 days, here are some pics of the wiring and (nearly) final product. I used a bunch of in-line wire connectors, insulated with shrink wrap and electrical tape instead of the gimmicky quick connects that were provided with the controller. I did this because no matter how good you are at soldering, joints are more likely to break loose than connected, shrink wrapped, electrical taped connections, plus you get the benefit of basically guaranteed waterproofing. I still need to add a rear brake rotor which is annoying because it involves removing the controller from the casing and disconnecting the phase wires. Despite missing the rear brake, I was able to take it around the neighborhood for a few miles. The front brake failed once (mechanical) because I didn't tighten the cable into the caliper hard enough; that was a little scary since I blew a stop sign but at least it wasn't a red light! The rear brake will be a project for about 2 weeks from now. Off to Mexico this Saturday!

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jonnybump   1 W

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Joined: Jan 31 2015 8:48am

Re: 8kw Enduro Frame Build

Post by jonnybump » May 22 2018 3:14pm

I have this frame - or at least one that looks exactly like it, it's not an EEB one or EM3EV one, but is holding up pretty well (survived a few knocks!). It is steel construction, I bought off a guy advertising on here and paid $350 shipped which I think is a bargain (viewtopic.php?f=31&t=81828&hilit=tank+f ... 0#p1303116). Mine weighs a tonne!

Out of interest - does yours have quite a bit of lateral play in the swingarm rubber bush? Mine has from new, I have just lived with it but always thought it left the handling a little sloppy.

Jon

Yermommy   1 W

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Joined: Mar 17 2018 1:18pm

Re: 8kw Enduro Frame Build

Post by Yermommy » May 29 2018 7:55pm

jonnybump wrote:
May 22 2018 3:14pm
I have this frame - or at least one that looks exactly like it, it's not an EEB one or EM3EV one, but is holding up pretty well (survived a few knocks!). It is steel construction, I bought off a guy advertising on here and paid $350 shipped which I think is a bargain (viewtopic.php?f=31&t=81828&hilit=tank+f ... 0#p1303116). Mine weighs a tonne!

Out of interest - does yours have quite a bit of lateral play in the swingarm rubber bush? Mine has from new, I have just lived with it but always thought it left the handling a little sloppy.

Jon
Mine fits pretty well, I haven't noticed any play at all.

Infinite Range   1 µW

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Joined: Dec 03 2017 4:40am

Re: 8kw Enduro Frame Build

Post by Infinite Range » May 31 2018 3:47pm

Very nice build! Im working on something similar!
The handlebar is quite large, why not use a BMX/MTC Endure Handlebar, where you have gained some additional space for a handlebar-Bag? something like this:

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