Ebike Project 72V HS3540 UK "build thread" +Videos!

oatnet · Nov 15, 2012

rui_fujino said:
I've got this full face helmet which are just like what you just described!

knighty said:
any more info on the helmet ?
I need one....

A wide variety of full-face Bike helmets are readily available (do an eBay search), but be aware that very few offer a level protection that is adequate for ebike speeds.

-JD

rui_fujino · Nov 15, 2012

knighty said:
any more info on the helmet ?

I need one....

bought an XL helmet online.... wasn't cheap... but it's crap..... and way too small... sits ontop of my head like a soup bowl :s

Check herefor more info!
personally its excellent helmet and hasn’t let me down! its easy to wear(comfortable), easy to carry, looks great!!!
some people who has had accident with it says it saved their lives!

oatnet · Nov 15, 2012

rui_fujino said:
personally its excellent helmet and hasn’t let me down!

If it "didn't let you down," you are saying you have had a crash in this helmet, and it protected you. Pics Please.

rui_fujino said:
its easy to wear(comfortable), easy to carry, looks great!!! some people who has had accident with it says it saved their lives!

Also note this quote from another rider, who likes it, but adds "I imagine a hard hit on asphalt will destroy the chin guard."

Nothing wrong with a lightweight helmet, as long as you are using it for lightweight duty and need lightweight protection. Don't expect to do a 25mph face plant wearing one of these on the street, and not be picking teeth out of the back of your throat.

-JD

rui_fujino · Nov 15, 2012

oatnet said:
rui_fujino said:

personally its excellent helmet and hasn’t let me down!

Click to expand...

If it "didn't let you down," you are saying you have had a crash in this helmet, and it protected you. Pics Please.

rui_fujino said:

its easy to wear(comfortable), easy to carry, looks great!!! some people who has had accident with it says it saved their lives!

Click to expand...

Also note this quote from another rider, who likes it, but adds "I imagine a hard hit on asphalt will destroy the chin guard."

Nothing wrong with a lightweight helmet, as long as you are using it for lightweight duty and need lightweight protection. Don't expect to do a 25mph face plant wearing one of these on the street, and not be picking teeth out of the back of your throat.

-JD

I recon the helmet can handle 25mph crash. given its a car you crash into not a concrete.
I say haven't let me down cos i used to have DH helmet and it was so heavy and keeps moisture inside nd it didnt do good job on hearing cars either.
This helmet is definitely not made for ebikers (30+mph) but its sth worth having and I find it safer since I can hear the cars around the corner or behind me. With motor cycle helmet, you wont be able to hear street sound at all!

TheBeastie · Nov 15, 2012

rui_fujino said:
TheBeastie said:

Looks like your going pretty fast
I think the ebike community has created a market for a new type of helmet, something in between a standard bicycle helmet and a motorbike helmet, well that's what I would want going at those speeds.

Click to expand...

I've got this full face helmet which are just like what you just described!

Good grief that is a awesome helmet!
That's exactly what I want to be wearing on my meager ebike at max speed of 40km/h. When I am at max speed I start thinking sure the top of my head should be ok at this speed but I feel I am going to loose the bottom half of my face.
Not cheap though at about $185. Where are the Chinese grey market copycats when you need them.
http://www.ebay.com.au/itm/2012-MET-Parachute-Full-Face-Mountain-Bike-Helmet-Black-Medium-NR-/160908204930

BATFINK · Nov 16, 2012

Did you get a headlight, this baby is awesome:
SKYRAY 5000 Lm 3x CREE XM-L T6 LED Bicycle bike HeadLight Light Headlamp

http://bit.ly/ZHTnlC

Sent using Endless-Sphere Mobile app

BATFINK · Nov 16, 2012

Did you get a headlight check out this baby it's awesome:
SKYRAY 5000 Lm 3x CREE XM-L T6 LED Bicycle bike HeadLight Light Headlamp

http://bit.ly/ZHTnlC

Sent using Endless-Sphere Mobile app

rui_fujino · Nov 16, 2012

BATFINK said:
Did you get a headlight check out this baby it's awesome:
SKYRAY 5000 Lm 3x CREE XM-L T6 LED Bicycle bike HeadLight Light Headlamp

http://bit.ly/ZHTnlC

Sent using Endless-Sphere Mobile app

That's one crazy badass looking light! I do have a pretty strong light but this is one step too far to use on the road...
I love it but then it's not worth buying for me :mrgreen:

BATFINK · Nov 17, 2012

heres my link to my thread on it versus the magicshine single LED, it can be used on 1,2 or 3 LED's

http://endless-sphere.com/forums/viewtopic.php?f=3&t=45604

rui_fujino · Nov 19, 2012

I'm currently building ebike (48v 1500w) for my friend and I was wondering if anyone got hall sensors (3) I can buy?
the build is not so fast conhis motor that i used to have (needs fixing and wires...). shouldnt take too long to build it!
Let me know if anyone got spare hall sensors to sell for me please!!

also the update!
I found a small crack on my front tire the other day...not sure if its worth buying a new front tire or not....

Also while cycling I heard sound clinking sound which I couldn’t figure out but it turns out to be broken spoke...
It seems like just snapped off...I've already made orders of 36 12g stainless spokes from holmeshobbies.com looking forward to get it!

rui_fujino · Nov 24, 2012

I haven't fixed up the spokes (new spokes hasn't arrived yet) but not too much of a problem to cycle for a week. So here is a new video in London :wink:
I'll try and find more interesting place to mount the camera soon(waiting for different mounting kit from ebay)
[youtube]lIL4-JzIapc[/youtube]

rui_fujino · Nov 25, 2012

Slightly unrelated but I've been working on my friend's Ebike build and I'm using my old gm motor.
I got new 8" gear puller and started fixing and cleaning the hub.

New honeywell s41 fitted and working great!

rui_fujino · Nov 27, 2012

I got my spokes today from Holmes hobbies!
the quality seems very good and they didnt take long at all!
I must say, It was little costy but from shipping to the UK not bad at all!
here is pics!

rui_fujino · Jan 11, 2013

Its been a while since my last post but here are some updates and news!
I've successfully completed ebike for my friend, here are some pictures!
I dont have picture of the bike before I made it but its simple model so you can imagine what it was like

Also, I've got upgrade to my front fork! (Finally! :mrgreen:

). I used to have rockshox dart3 (ok fork, the best thing about it was I never needed to look after it

)
I now have Fox 32 Talas 140 RL (got it serviced last week). here are some pics from the upgrade!

I'll make some new video once weather gets better. hopefully I can get new angle of the ride! (i've recently purchased more camera mounts so I can fit the camera anywhere on the bike!)

rui_fujino · Jan 18, 2013

It has started to snow heavily in uk and I dont want to spend so much on snow tire....

SO! :!:

Here is what I DID!!! :mrgreen:

Its just few zip ties tide around the tire. This creates slit between the layers of snow which causes snow to not stick to your tire thus increase the grip while normal tire just get covered in snow after few meters.

rui_fujino · Jan 29, 2013

I've got my first video finally out! Took me a long time to get out there in cold and snow but finally got something from snowish london view!

Unfortunately I couldn’t get different camera views added but this video is the first one since i've upgraded my front fork to Fox Talas!

Enjoy!
[youtube]CEeN_XvlyK8[/youtube]

boo · Mar 4, 2013

informative build indeed...
how much is your actual range? does it have a good hill climbing?
thanks - im researching for my 2nd build and considering same motor as yours.

rui_fujino · Mar 4, 2013

boo said:
informative build indeed...
how much is your actual range? does it have a good hill climbing?
thanks - im researching for my 2nd build and considering same motor as yours.

I'm glad my build thread is helping others

so far I've done about 60 cycles on my battery packs, 1500miles so...quick calculation tells me I do an average of 24miles on a charge.
I do have quite steep hill near by and I can go up as fast as 30-35mph but I do have 52t/11t combo so I can pedal up to 40mph which is very helpful when I need to go up the hill or go faster then 45mph. :mrgreen:

I personally have no regret by getting this motor considering how reliable its been and every time i ride after the full charge it feels so good!!

rui_fujino · Mar 24, 2013

I've decided to do a MASSIVE up grade by changing this bike to new frame!
I've picked FS bike frame already and got it(picture will be posted soon!). now, I've got many new parts coming in soon but one problem.
I want to have 52T triple chainring on front BUT rear swingarm is in my way therefore I can not fit 52t ring. like this:

The picture is not my bike but you get the idea. Any solutions??

thanks!

whereswally606 · Mar 25, 2013

if you havent already get a dnp 11t - 28t free wheel @ebikes.ca or otherwise. losing 3 teeth at the rear is upping the ratio more than 10 at the cranks.Other wise you need a bb with a longer spindle.

just read a couple of posts back, i realise now you already have the smallest rear chain ring.

Trackman417 · Mar 25, 2013

Simple: Don't use a 52 tooth chainring

:wink:

rui_fujino · Mar 25, 2013

I think i'll try and find longer BB and good triple chainrings....
Also, since I wanted to add some bike porn to my thread here is my new frame!
Specialized Epic!

Its a great frame with nice triangle space for batteries. now I dont need to worry about rear sus getting in the way of batteries.
Also, This frame is MUCH lighter!
on -ve news...I was charging my battery pack late last night and accidentally did this...

good thing it was after charged and is balance leads!

rui_fujino · Apr 7, 2013

Okay so here are updates to all the build steps so far! enjoy!

I had to cut the edge off the side for derailleur clearance but my blade snapped...Very strong torque plate :!:

I got 122.5mm internal shimano BB which works perfect! leaves 4mm clearance from the drop-out
View attachment 6

View attachment 2
The white brake+shifting cable are fitted so far and new shimano brake/shifter fitted too.
cleaned everything before fitting onto the new build!

rui_fujino · Apr 24, 2013

Here is a Looong waited new ebike video!
this is completely finished build of my 5th ebike! since the frame is lighter my acceleration feels so much better!
[youtube]lOHYh_L_98Y[/youtube]

rui_fujino · Apr 24, 2013

oh! I forgot to upload the final build pictures! here you go!
View attachment 2

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