Fatbike with 3500w Bafang G510 Ultra max

Show off your E-bike creation here.
Post Reply
Sinhu   10 mW

10 mW
Posts: 30
Joined: Aug 04 2019 9:55pm

Fatbike with 3500w Bafang G510 Ultra max

Post by Sinhu » Sep 20 2020 10:19pm

Hi !

My fatbike build have started, and i’m planing to post the process to working bike.

I starded with a frame i got used, sanded and painted it.

The frame came from this bike:
342CA131-BEBE-43DE-A683-859A43072365.jpeg
Momas f1000
342CA131-BEBE-43DE-A683-859A43072365.jpeg (104.85 KiB) Viewed 689 times
Used bedliner paint
C9A4A674-F3C9-4C16-BF3A-4FC6690EC9F1.jpeg
Titanium shell paint
C9A4A674-F3C9-4C16-BF3A-4FC6690EC9F1.jpeg (110.13 KiB) Viewed 689 times
Paint job went very well
5D10D33F-D58C-4629-89D8-D903DDE9B4F7.jpeg
Finish
5D10D33F-D58C-4629-89D8-D903DDE9B4F7.jpeg (99.38 KiB) Viewed 689 times
660FB377-5D72-41A4-9742-40F8BF4EB60E.jpeg
Finish
660FB377-5D72-41A4-9742-40F8BF4EB60E.jpeg (100.54 KiB) Viewed 689 times
8071D4E3-73BE-40C2-B8CC-7D7B5BEE20DC.jpeg
Finish
8071D4E3-73BE-40C2-B8CC-7D7B5BEE20DC.jpeg (105.14 KiB) Viewed 689 times
Painted feontfenders to
58C83552-265B-436C-B3DB-642CFE009069.jpeg
Front fender
58C83552-265B-436C-B3DB-642CFE009069.jpeg (94.58 KiB) Viewed 689 times
Back fender is plastic
791F53F3-3957-4D8A-A623-1A47ED9C8FB8.jpeg
Fender for the backwheel
791F53F3-3957-4D8A-A623-1A47ED9C8FB8.jpeg (186.24 KiB) Viewed 689 times

Motor i have orderd from Innotrace in Germany, that is the developer and supplier to wattwagon that offer the 2500w version, Innotrace have upgraded version of this controller that gives 3500w of power with 52v80Amp controller
4B23EFE2-0ED3-4AE2-B99D-8238492ACC71.jpeg
Wattwagon
4B23EFE2-0ED3-4AE2-B99D-8238492ACC71.jpeg (45.92 KiB) Viewed 689 times


A callange is battery, and orderd the biggest downtube battery case on the marked. Polly with room for 91 cells
4B4E7362-6703-4A0E-A273-1B5D41F31DF0.jpeg
Polly downtube
4B4E7362-6703-4A0E-A273-1B5D41F31DF0.jpeg (44.39 KiB) Viewed 689 times
Have found a drawing of fiting 98 cells in this battery case, that means 14s7p 98cells and are going ro use a 50A BMS. Do not think i will be other then some second above 50A and peak A is 120A so i think i’ll be fine.
5DF80D3B-3B5A-41DC-9DA0-4C494241B459.jpeg
Polly with 98 cells
5DF80D3B-3B5A-41DC-9DA0-4C494241B459.jpeg (72.16 KiB) Viewed 666 times
Daly BMS
E6B88251-C334-4C23-A4AC-CC1B9F6158A9.jpeg
Bms
E6B88251-C334-4C23-A4AC-CC1B9F6158A9.jpeg (58.69 KiB) Viewed 666 times
Not 100% sure, but looks like it will be Samsung 18650 30Q cells i will use. And if i can fit 98cells in 7p i will have a battery with 52v21Ah
89E6D18D-5F13-4D8D-9744-4B641A067CB9.jpeg
Samsung 30Q
89E6D18D-5F13-4D8D-9744-4B641A067CB9.jpeg (42.64 KiB) Viewed 666 times
As i wait for motor and rest of the part i have startet to fit some parts. Today i’m fiting backfender.
D93722C3-F68A-4624-A182-CF150D2FBFEA.jpeg
Fiting back fender
D93722C3-F68A-4624-A182-CF150D2FBFEA.jpeg (197.93 KiB) Viewed 666 times
Found some prefabricated holes, proberly for draining the frame tube pipes. Was perfect for mounting the fender after treading the holes with M5:)
A690DBA2-327C-43F7-BAF3-B06855BE01F4.jpeg
Treaded prefab holes With M5
A690DBA2-327C-43F7-BAF3-B06855BE01F4.jpeg (55 KiB) Viewed 590 times
B1DEDC76-3ECC-4F9C-9C32-78DB1DD778A3.jpeg
Treaded prefab holes
B1DEDC76-3ECC-4F9C-9C32-78DB1DD778A3.jpeg (59.58 KiB) Viewed 590 times
Front suspension i desided on trying the upside down design as DNM US6 15x150mm thru axl.

I struggled to find a suspension fork with 15x150mm for strait frame tube, only tapperd fork was availble for fatbike. Solution was a semi integretad head bearing.
1B21DA96-B9F3-47A7-90FD-04367029D9D9.jpeg
Head bearing
1B21DA96-B9F3-47A7-90FD-04367029D9D9.jpeg (85.39 KiB) Viewed 585 times
C3787627-27E5-4650-A8F4-B287ABC21830.jpeg
Suspension upside down design
C3787627-27E5-4650-A8F4-B287ABC21830.jpeg (49.83 KiB) Viewed 657 times
The head bearing set is in place.
B78D46FC-2B34-4743-AE95-A9A18664ADCF.jpeg
Headset
B78D46FC-2B34-4743-AE95-A9A18664ADCF.jpeg (91.84 KiB) Viewed 578 times
Trying on the front wheel, think it’s looks good :)
AB6F55C9-57B6-443F-9A24-01FA1D8AB1E2.jpeg
Wheels on bike
AB6F55C9-57B6-443F-9A24-01FA1D8AB1E2.jpeg (126.72 KiB) Viewed 576 times
Found the wheels at XXL with reflecting rim tape, 90 mm thru axel 15x150mm front and 12x190mm rear
A1AAAC17-CDC2-496C-AF37-0EDB0EFC8DDC.jpeg
White 90mm rims
A1AAAC17-CDC2-496C-AF37-0EDB0EFC8DDC.jpeg (94.83 KiB) Viewed 289 times
Fitting a seatpost with suspesion, simpel and cheap but a sweet extra on a hardtail :)
DC07D0FA-CA95-4D74-8ED0-C558F2B61463.jpeg
Suspension seatpost
DC07D0FA-CA95-4D74-8ED0-C558F2B61463.jpeg (160.38 KiB) Viewed 576 times
With the frontsuspension it’s a bit problematic to mount it. Found a cheap extender bolt for the head tube with a mounting bracket.
3705C181-31DA-4008-860D-7FA1D5FC36E2.jpeg
Mounting solution
3705C181-31DA-4008-860D-7FA1D5FC36E2.jpeg (81.8 KiB) Viewed 550 times
Need to find some rings for the suspension arms to screw the suspesion rod’s from the fender.

And with the frontlight mounted on the bracket it looks clean :)
118A8CA9-918F-4FEC-B2BD-53808626B1CA.jpeg
Front fender with Supernova E3 frontlight
118A8CA9-918F-4FEC-B2BD-53808626B1CA.jpeg (160.39 KiB) Viewed 550 times
As the Innotrace controller dont have light support, the solution was a Supernova E3. With this frontlight i can run power directly feom the battery (12-60v) with a line out 6v to rearlight and a on/off push button.

The big polly battery case arrived today :)
Last edited by Sinhu on Oct 05 2020 7:35pm, edited 11 times in total.

HoraceLai   10 mW

10 mW
Posts: 22
Joined: Aug 25 2013 10:41am

Re: Fatbike with 3500w Bafang G510 Ultra max

Post by HoraceLai » Sep 21 2020 9:26am

Fenders look really good. Where did you buy them?

Sinhu   10 mW

10 mW
Posts: 30
Joined: Aug 04 2019 9:55pm

Re: Fatbike with 3500w Bafang G510 Ultra max

Post by Sinhu » Sep 21 2020 10:39am

Hi !

The fenders i had to order feom the uk.
D36567FA-1E3F-4719-A53F-8A441D159569.jpeg
Web adr fenders
D36567FA-1E3F-4719-A53F-8A441D159569.jpeg (122.75 KiB) Viewed 648 times

Sinhu   10 mW

10 mW
Posts: 30
Joined: Aug 04 2019 9:55pm

Re: Fatbike with 3500w Bafang G510 Ultra max

Post by Sinhu » Sep 28 2020 3:44am

7AF5CCF1-6C04-4410-BB5F-2F8944499647.jpeg
Test fitting the new battery case
7AF5CCF1-6C04-4410-BB5F-2F8944499647.jpeg (88.89 KiB) Viewed 505 times
The big polly battery case

Not much more room, fits perfect :)
7C723464-BF81-42E0-B47F-9F36698C2E36.jpeg
Big polly battery
7C723464-BF81-42E0-B47F-9F36698C2E36.jpeg (238.5 KiB) Viewed 541 times
Today the cells arrived. The prodjekt i starting to come together :)
39B49D58-BE45-4E75-968D-DFFFBD382FDD.jpeg
Samsung INR18650-30Q
39B49D58-BE45-4E75-968D-DFFFBD382FDD.jpeg (298.64 KiB) Viewed 405 times
Very positiv test of the 30Q cell
https://lygte-info.dk/review/batteries2 ... %20UK.html


Starting to mount breaks and gear on the bike.
For breaking i have desided on Shimano 203mm breakdisk front and rear.
BB0A596C-F4A8-4DC6-BCE5-52C4E7A446A9.jpeg
Shimano SM-RT76L 203mm breakdisk
BB0A596C-F4A8-4DC6-BCE5-52C4E7A446A9.jpeg (189.19 KiB) Viewed 343 times
And 4 piston break calipre.
ED6FAD36-E593-4D44-A17E-C3887762CC6E.jpeg
Shimano BR-MT 520 4 piston calipre
ED6FAD36-E593-4D44-A17E-C3887762CC6E.jpeg (162.16 KiB) Viewed 343 times
CE6E561E-6C99-432E-AB39-5B5DBB284236.jpeg
Shimano BR-MT 520 4 piston calipre
CE6E561E-6C99-432E-AB39-5B5DBB284236.jpeg (128.7 KiB) Viewed 343 times
You find more expensive breaks but i hope these will do the job.

Break levers i use Shimano Deore with mount for a SLX 10speed shifter.
0AD62640-51F4-4329-B77D-C4188216AF20.jpeg
SLX shifter 10speed on BL-M615 break leaver
0AD62640-51F4-4329-B77D-C4188216AF20.jpeg (173.24 KiB) Viewed 343 times
636FD38C-B73A-44C5-9E36-275BCB9D002F.jpeg
Shifter mount on breakleaver
636FD38C-B73A-44C5-9E36-275BCB9D002F.jpeg (119.65 KiB) Viewed 343 times
The controller from Innotrace do not have out put for front and rear light, so i try connect some lights i found on aliexpress.

First i try to find a place for the DC-DC step down and fuse.
A0138412-0D1D-4243-A860-AD7AA90C6E44.jpeg
Dc-dc stepdown to 12v and fuse fit inside left motorcover
A0138412-0D1D-4243-A860-AD7AA90C6E44.jpeg (196.91 KiB) Viewed 340 times
And i need a switch
656C52C4-F294-48C6-86E0-E9B67018DFF3.jpeg
On and off swith
656C52C4-F294-48C6-86E0-E9B67018DFF3.jpeg (190.71 KiB) Viewed 340 times
For front light i use a Led light in a aluminium casing
447CFC0F-D9F8-4F7E-9EF3-21C808D6796F.jpeg
Led lights in alu casing
447CFC0F-D9F8-4F7E-9EF3-21C808D6796F.jpeg (120.68 KiB) Viewed 340 times
Rear light i will use a led strip on both side of the rear wheel
D703A75F-CF5E-46C3-BC3D-C630563A4EE9.jpeg
Led strip
D703A75F-CF5E-46C3-BC3D-C630563A4EE9.jpeg (50.96 KiB) Viewed 339 times
8EADB475-8E1A-4845-916C-BAB99EA5B215.jpeg
Rear light
8EADB475-8E1A-4845-916C-BAB99EA5B215.jpeg (59.21 KiB) Viewed 339 times
Still waiting for motor and battery, and it will take 2-3 weeks before every thing is here.

But some small parts and nick nack lands in the mailbox from china :)
83F538AC-3662-4510-83B8-3C1DEE42DF5F.jpeg
Platform MTB pedals
83F538AC-3662-4510-83B8-3C1DEE42DF5F.jpeg (295.9 KiB) Viewed 237 times
Last edited by Sinhu on Oct 08 2020 7:43am, edited 7 times in total.

BeachRider2016   100 W

100 W
Posts: 148
Joined: Jul 13 2016 10:42am
Location: North Carolinas

Re: Fatbike with 3500w Bafang G510 Ultra max

Post by BeachRider2016 » Sep 30 2020 7:55am

I ordered the same battery case to build a 14s 98 cells pack as well. Followed.

Sinhu   10 mW

10 mW
Posts: 30
Joined: Aug 04 2019 9:55pm

Re: Fatbike with 3500w Bafang G510 Ultra max

Post by Sinhu » Oct 01 2020 4:49pm

Have seen a couple of drawing of 98cell version, but fitting a 60+A BMS as well seems difficult.

Would love seeing your solution

Tomblarom   1 mW

1 mW
Posts: 13
Joined: Jul 20 2018 1:33pm

Re: Fatbike with 3500w Bafang G510 Ultra max

Post by Tomblarom » Oct 05 2020 11:18am

Hey guys, I'm that person, who designed the layout. Haven't got time to 3D-print the parts yet and test fit everything. Going to give feedback and publish the whole design soon.
https://photos.app.goo.gl/zHAfkTd9oUuBhV2t8

For the BMS, I use this chinese Smart BMS with BT and replace the MOSFETS and shunts to easily achieve 60A, while having a max height of 10mm. Excited to see how this works out.

I'm using VTC6 and discharge with a max of 50A. Having 7P, each cell won't reach more than ~7A. This keeps the cells temperature pretty low. Check the discharge/temperature chart, of the cell you're planning to use. Otherwise stay safe and build an 14S6P or 13S7P.

Sinhu   10 mW

10 mW
Posts: 30
Joined: Aug 04 2019 9:55pm

Re: Fatbike with 3500w Bafang G510 Ultra max

Post by Sinhu » Oct 05 2020 12:10pm

I’m sorry not credit your design, i will of course delete the drawing from the post if you prefere ?

Or you can ad to this tread with your battery build and progress fit 14s7p in the big polly case ?

No bad intesion using your design, just impressed bye the creativety :)

BeachRider2016   100 W

100 W
Posts: 148
Joined: Jul 13 2016 10:42am
Location: North Carolinas

Re: Fatbike with 3500w Bafang G510 Ultra max

Post by BeachRider2016 » Oct 17 2020 10:21pm

Tomblarom wrote:
Oct 05 2020 11:18am
Hey guys, I'm that person, who designed the layout. Haven't got time to 3D-print the parts yet and test fit everything. Going to give feedback and publish the whole design soon.
https://photos.app.goo.gl/zHAfkTd9oUuBhV2t8

For the BMS, I use this chinese Smart BMS with BT and replace the MOSFETS and shunts to easily achieve 60A, while having a max height of 10mm. Excited to see how this works out.

I'm using VTC6 and discharge with a max of 50A. Having 7P, each cell won't reach more than ~7A. This keeps the cells temperature pretty low. Check the discharge/temperature chart, of the cell you're planning to use. Otherwise stay safe and build an 14S6P or 13S7P.
Please do post the 3d printed spacers when it’s done. I got my case in the mail today and itching to get it assembled. :mrgreen:

Tomblarom   1 mW

1 mW
Posts: 13
Joined: Jul 20 2018 1:33pm

Re: Fatbike with 3500w Bafang G510 Ultra max

Post by Tomblarom » Oct 18 2020 2:50am

I added pictures to the Google photos album. Have a look! It was simply not enough space... my 3D printer was not precise enough and my cells had 18,3mm diameter. Maybe you are able to bring this to work :)

EDIT: Published my designs. https://www.thingiverse.com/thing:4627055

Post Reply