27.5 plus mid drive

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Lenk42602   10 kW

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27.5 plus mid drive

Post by Lenk42602 » Oct 19 2018 7:00pm

Haven't put a build thread up in a while.

Targeted goals:
2kw power ,
Battery pack 40a continuous capable
26 miles range minimum,
Total bike weight(including batteries) of 65 pounds max.
Completely water/weather proof
Multi surface/condition capable
Feels like a bicycle


Was looking at purchasing a turn key mid drive bike but the Power Output/$ just didnt make any sense. Bike's assembled and waiting on brakes. Fabbed the battery mounts. Battery is en route. I'll be fabbing a steel enclosure for it.
DSC00999.JPG

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » Oct 31 2018 7:13pm

Bike's completely built. Brakes and shifter all set up, probably ride to work a few times to get the bicycle bits sorted. Weighs in a 30.5 pounds as pictured with pedals, 2.8 tires, thru axles, and the main triangle brackets attached for mounting the battery enclosure.
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here's a shot of one of the brackets - its 3/32 steel that clamps around the tube, 3/16 tabs welded to it that will receive the battery enclosure. Using ABA hose clamps to draw up the brackets against the tubing.
KIMG0442.jpg
viva la hose clamps! circa 2007..... coming full circle...
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battery should be here before the drive system. next up is documenting the battery enclosure.

Just wanted to add, really thought hard about buying a nice specialized or BH Easy Motion type pedelec - although those bikes are extremely well integrated from a design perspective, they just lack the oomph/dollar i need to stay interested in an ebike... Interested to see how the battery and drive unit for this project will compare.

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » Nov 10 2018 5:06pm

Started tacking up the enclosure this morning. Using 1/2 square and 1/2 round tube. found some gussets in my scrap pile left over from a different project I''ll be using for holding the battery pack securely.

em3evpack enclosure 1.jpg
em3evpack enclosure 2.jpg
em3evpack enclosure 3.jpg
Ran out of mig gas, so I will probably get back to it monday

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » Nov 11 2018 6:20pm

Got Gas! moving forward..
em3evpack enclosure 4.jpg
em3evpack enclosure 5.jpg
em3evpack enclosure 6.jpg
em3evpack enclosure 7.jpg

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » Nov 12 2018 1:54pm

more accomplished. Next are the side corner gussets to secure the battery. then receiving mounts for the frame brackets. Then clean it up and send it to PC.
em3evpack enclosure 8.jpg
em3evpack enclosure 9.jpg
em3evpack enclosure 10.jpg

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » Nov 16 2018 6:02pm

corner gussets made. cleaned up battery frame. need to drill and tap for corner plate m5 attachment screws.
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Last edited by Lenk42602 on Nov 18 2018 7:01pm, edited 1 time in total.

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » Nov 18 2018 7:01pm

only thing left is drill and tap corner plate m5 attachment screws, powder coat. got it all together today. Should be lining up well with arrival of the X1 kit.
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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » Nov 19 2018 6:27pm

heading to powder coat wednesday. should see it back next monday/tuesday

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » Dec 01 2018 4:22pm

Battery enclosure all finished. As pictured 46 pounds. Should have a sub 60 pound machine!
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Now the wait is on for the GNG X1 Pro!

ichiban   10 W

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Re: 27.5 plus mid drive

Post by ichiban » Dec 11 2018 10:22am

It is a nice and sturdy battery compartment build !
And what size is your EM3EV battery ? ...S...P ?

Have not seen any motor you are using with your kit. Hub or mid-drive ?

My 27.5 hardtail does not have a big triangle space like yours, so the 14s7p pack is needed to be squeezed into that tight space with dense plastic cell holders. Airflow might not be perfect.

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » Dec 11 2018 9:35pm

Thanks!

i'm planning on using a mid drive from Cyc Motor Ltd.

GNG x1 Pro. Its on order and they are not quite yet ready to ship the first production units out.

https://www.cycmotor.com/x1-pro

Pack is 14s 6p from EM3EV. Samsung 30q cells

https://em3ev.com/shop/50v-14s6p-small-triangle-pack/

Should be a nice balance between power/weight.

cheers

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » May 17 2019 12:37pm

Motor arrived. I will be building up this weekend.

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » May 18 2019 5:41pm

mock up. 63t ring set up is tight enough to not need the tensioner.
KIMG0602.jpg
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gotta do better than that strap securing the motor brackets to the down tube. Going to fab up a bracket that captures an unused H2O bolt and tie it to some unused holes on each bracket face.

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » May 19 2019 11:25am

motor is installed. chain line is pretty good right now, may have to move the chain side spacer to the non drive side. made a motor strap like the Tangent drive solution.
KIMG0604.jpg

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izeman   10 GW

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Re: 27.5 plus mid drive

Post by izeman » May 19 2019 11:40am

When i saw your opening post I thought: NO NO CLAMPS. You can't do that, but i must say the finished solutions looks very good. Sturdy and professional. :bigthumb:

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » May 19 2019 4:43pm

not a fan of the clamps, but those hydroformed tubes have really odd shape/taper to them.

CNC'ing clamps would be a huge effort.

battery is getting charged.
KIMG0605.jpg
gotta clean up some wires and then mount the speedo sensor. should be up and running in a few days!

Len

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » May 19 2019 8:32pm

Bike's all finished, ready for a test ride. Might commute in to work Tuesday.

Total bike weight - 56.5 pounds

first impressions of kit -

well built/executed, great attention to detail with this, everything fits, chainline is good after first set up, I can tweak it if need be by adjusting the spacers at the bb shell, freewheel on crankset has a little run out (visual) but nothing excessive.

Really digging the display.

I will get into the settings via app tomorrow.

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n2mb   100 W

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Re: 27.5 plus mid drive

Post by n2mb » May 19 2019 9:13pm

Nice battery mount! Where did you get that? I had a similar triangle pack, but couldn't figure out a nice way to mount it. Using a triangle bag seemed janky.

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » May 19 2019 9:18pm

n2mb wrote:
May 19 2019 9:13pm
Where did you get that?
built it in the garage

thanks!

Electricglider   10 mW

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Re: 27.5 plus mid drive

Post by Electricglider » May 20 2019 1:04am

Congrats on a super clean and nice ride!
I am waiting for my own X1, this is very inspiring!

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Ecyclist   1 kW

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Re: 27.5 plus mid drive

Post by Ecyclist » May 20 2019 10:34am

Very nice build. It looks like you will be under 50 lb.
Don't expect from life to be easy and then it will be.
My builds:
Avian with hypocycloidal drive https://endless-sphere.com/forums/viewt ... 2#p1318056
2016 GNG extreme drive https://endless-sphere.com/forums/viewt ... 28&t=82252

Rube   100 W

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Re: 27.5 plus mid drive

Post by Rube » May 21 2019 5:07am

Great build and thanks for sharing. Very nice mix of power with low weight and a touch of hand crafted design. The floating triangle battery imbues a lightness to the asthetic.

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Lenk42602   10 kW

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Re: 27.5 plus mid drive

Post by Lenk42602 » May 21 2019 3:53pm

first run up and down the street. didnt bother playing with the settings, just jumped on it and hit the throttle.

Oh yeah :P

power! downloading the app now top start tweaking.
KIMG0612.jpg
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Raketemensch   1 W

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Re: 27.5 plus mid drive

Post by Raketemensch » May 21 2019 10:23pm

That is a really nice, clean look.

999zip999   100 GW

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Re: 27.5 plus mid drive

Post by 999zip999 » Aug 15 2019 8:38pm

How did you like that middrive ?

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