PUCH Maxi electro build (4 offroad use)

Show off your E-bike creation here.
User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

PUCH Maxi electro build (4 offroad use)

Post by puchwudi » Jun 17 2015 5:08pm

Hello guys!

This is my first post in the ES community :oops: I really love this platform!
About two months ago, I was thinking about a new project for myself. Soo I got the idea to convert an old Puch Maxi to an elctric offroad bike. My goal is to imporve my knowledge about electromobility and to show off what i learned in the last years..

Main Electronik components:

- Cromotor V2 (QS Motor)
- Lyen 18FET controller (eb318)
- Headway 24S1P (38120)
- 2x 24S 40A BMS (leadyo battery)
- TCM-400 24S Carger (4A cont.)

My father brought my a rusty and dirty frame, as a present from his chief to me. This was motivation enough for me to create a nice bike :wink:

Image

_____________________________________________________
READY TO RUN! (25_10_2015) But go on reading!!! = )

Image

_____________________________________________________

I threw away all the redundant parts and cleaned up the frame. the first things I was thinking about ... Where can I place the battery? Well the bike has a gas tank on the front side of the frame, which is integrated in the whole mechanical construction. removing or opening this would decrease the mechanical strength of the frame...So I am place the battery pack between the steering head bearing and the socket for the seat.

Image

The next steps was to plan the design of my Headway pack. I use the single cells in a row, as you can see. The plastic holder are build by a 3D-Printer.

Image

Image

Image

In the meantime I got to know a nice guy, which supports me with all the mechanical / welding work, so we cleaned the frame to a delight version :P

Image

Image

Image

So the frame got a second axle for the bike crank. The front suspension is a Marzocchi
888 VF2 with the 20mm axle. A good friend of mine mounted the tires on the rims and fitted the cromotor. My spokes are 4mm thick, so at the back I use a 17" rim (1.80") and at the front a 17"(1.20") with Sawa Sport tyres ;)

Image

Well after getting the frame and tyres ready, we started with the lever out of wood for checking the poition of the seat and so on...

Image

The lever consists of a very robust aluminium profile which is welded with very strong drop outs for the Cromonster.

Image

Image

Image

I hardly found the perfect fork for our frame, so we used a scooter fork with an extra gas bottle where you can choose the strength of the bumper.

Image

We left the workshop at 6 pm today :wink:

Image

In the following days I will upload some electronic pics :lol: :lol:

I will keep you UP to DATE :mrgreen:
Last edited by puchwudi on Oct 31 2015 11:57am, edited 4 times in total.

User avatar
beast775   100 kW

100 kW
Posts: 1207
Joined: Jul 05 2007 11:55am
Location: victoria british columbia

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by beast775 » Jun 17 2015 8:19pm

Welcome puchwudi :) ,that is going to be a fast puch-E or E puch,maxi puchE. awesome build so far,going to be interesting where you put the batteries.
2 FINGER SALUTE TO ESSO.no buying gasoline for 14 years now.
I spent all my money on bicycles women and beer the rest i just wasted.

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by puchwudi » Jun 18 2015 6:04am

Good morning : )

Before putting together the electronic stuff, I created a simple schematic, for getting an overview of all cable / connectors I nedd.

Image

Now I will show you some electronic components that I am using for my project. As described on the top the battery consists of plastic holders, which connect 6 cells mechanical with each other.

Image

Those holders consist of a special mixture of plastic and carbonfiber, its really hard to destroy them : P The battery holders have to get about 65 degree, so the material gets very soft and you can insert the cells very smooth.

Image

The whole pack consists of 4 holders (4 x 6 cells), they are connected with 2 hole plate connectors. Putting those parts together makes it very compact and stiff. But I am going to build it in a metal housing, therefore I will connect the pack to a transparent plastic plate, which gives a nice look to the whole bike :mrgreen:

Image

The plate was just a quick prototype! ;) I am getting CNC milled from a friend of mine ...

For the security of my battery I have two 24S 40A BMS boards, which have a higher balance current and a lower serial resistor :lol: Well, I had to prepare the balance lines (2 in 1 adapter)...

Image

Image

I use the 18 Fet Controller from Lyen for my Cromotor, but what I didnt like were those thin cables between source and controller ;) So I updated them to 8AWG silcion cable... I am also thinking about changing the caps ...

Image

Image

Image

Image

Image

I havent seen the inside of a hubmotor before, so opened the side plates and checked the motor from inside :lol:
Those guys did a really nice work! double hall sensor, 10mm² phase cables, everything perfect :)

Image

Image

Does anyone have good tips for me, how I can safe the motor from water? painting? loads of silicone? milling holes?

Thanks :lol:

litespeed   100 kW

100 kW
Posts: 1373
Joined: Aug 11 2010 4:42pm
Location: St. Peters, Missouri

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by litespeed » Jun 18 2015 6:21am

Great build!

Tom
I'm married so you know I'm no stranger to pain!

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by puchwudi » Jun 18 2015 6:29am

@beast775: Thank you very much! :) the battery will be placed in front of the seat! ;)

@litespeed: Thanks ;)

User avatar
madin88   100 MW

100 MW
Posts: 2954
Joined: May 27 2013 2:02am
Location: Austria

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by madin88 » Jun 18 2015 7:00am

nice conversion! i believe you are the first one who converts a puch maxi this way. when its finished, people hardly will believe you that it was one before :) its definitely unique.

on the shematic i noticed you are going to connect the throttle direct to the controller. it would be better to connect it to the CA. Im not sure if CA 2.3 can do, but version 3 supports a thermistors therefore you can protect the motor and it also has other useful features.
the AS150 connectors i have tried once, but the precharge resistor blew when i used it with 22s battery. you have similar voltage so better prepare yourself that it will be dead after first use :P i would suggest to use Jeti antispark connectors (5,5mm should be enough in combination with your fat wires) or build your own circuit.

looking forward to see it running and how you like it. i wish you success.
- 10kW belt drive with Neumotor 8057: viewtopic.php?f=30&t=91144&start=50#p1377787
- Fully road legal (L1E approval) e-bike based on Votec V-FR frame
/ MXUS 3T / 17" Mitas MC11 / Adaptto Max-E / 20s12p 25R
- KTM Hardtail Pedelec / eZee V2 6T / 27,5" / Kelly KBSX @ 1,5kW / Torque PAS / CA-V3 / 13s4p Sanyo GA in Shark case

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by puchwudi » Jun 18 2015 7:21am

Hello Maddin!

Thanks for your positiv feedback! It will definitely be unique! ;)
Whats the difference between conecting the throttle to the controller / CA?
Nice that you gave me those informations, but I already bought them :P So I will try them out for sure(want to see them blowing up). I will buy the JETI connector if necessary. Hope we can have a ride If I finished ;)

wudi

User avatar
madin88   100 MW

100 MW
Posts: 2954
Joined: May 27 2013 2:02am
Location: Austria

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by madin88 » Jun 18 2015 9:48am

puchwudi wrote: Whats the difference between conecting the throttle to the controller / CA?
the CA will protect the motor from overheating if you wire up a thermistor and have the throttle signal going through it. even a Lyen 18FET can overheat cromotor in short time when you do lots of stop and go or climbing steep grades..
the temperature limit you can configure in the CA and it also has other throttle featurers which might be useful.
Hope we can have a ride If I finished ;)
would be nice :)
- 10kW belt drive with Neumotor 8057: viewtopic.php?f=30&t=91144&start=50#p1377787
- Fully road legal (L1E approval) e-bike based on Votec V-FR frame
/ MXUS 3T / 17" Mitas MC11 / Adaptto Max-E / 20s12p 25R
- KTM Hardtail Pedelec / eZee V2 6T / 27,5" / Kelly KBSX @ 1,5kW / Torque PAS / CA-V3 / 13s4p Sanyo GA in Shark case

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Puch Maxi (50ccm) Conversion to Electro Maxi

Post by puchwudi » Jun 22 2015 9:38am

Hej guys!

I had a great weekend full of success! ;) The bike can stand on his own feet!!! :lol:

On Friday I finished the aluminium wing, but that wasnt so easy ... the hubmotor has different distances (from middle to each side) so the normal straight wing arms wouldnt fit on the prepared hull on the frame.

Image

With the drawing you can easily understand my problem : )

Image

This shows how the wing would look like with the straight arms.

the solution -->

Image

The right side has a parallel shift of about 20mm, now it fits perfect through the hull. I had to think about a cool mount for the rear hydraulic brakes ( CODE Avid 4-piston), so I milled a easy adapter for the right wing arm.

Image

To center the mount, i put the brake body on the brake disc on the rear disk an pushed the brake. After this we welded the two parts together.

Image

Image

After this was done, I ran through the whole cellar and looked for a bicycle seat, just for tests :) To my surprise I also got a never used shimano aluminium foot pedal, which is in my opionion very light.

Image

So I mounted all mechanical parts, which are ready to mount, together and this is what came out ...

Image

Image

I had the find the right positon for my back fork, so I compared the distances between pedal and seat with my bicycle and I really have to say that they are pretty much the same (after loads of tries :P). At the beginngin I had the problem, that the fork was set to low, so I could hardly touch the ground with my legs and it was also impossible to use the pedals like on a real bike... but now I am happy with the whole chassis.

Image

Image

Image

Image

See you! :)

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by puchwudi » Jun 22 2015 9:58am

On sunday I started using glas fiber mat for building my own headlamp.
Starting with creating an form out of styrofoam...

Image

The cheapest way to cut styrofoam is a soldering iron and a metal rail for a nice line.

Image

After cutting out the simple form (200mmx180mm) I started grinding the surface with a special grater.

Image

I couldnt decide which design would be the best, so I build two different ones ;)
After this, I mounted them on an old peace of wood with a universal superglue.

Image

Starting with painting the styrofoam with epoxy gum (two times because it sucks into the foam)

Image

Waiting for some hours ... then I raised them with a seperating wax and a seperating stale.

Image
______________________________

Image

1. Layer of glas fiber

Image

2.Layer

Image

The last one is a special material out of fiber glas, for a nice surface and a good mechanical stability.

result of three layers of fiber glas ...

Image

today I will have a look @ them, I am really excited how these babies look like today! if they look good, I will think about creating my own fender (front / rear)

Enjoy your day :mrgreen:

User avatar
Drunkskunk   100 GW

100 GW
Posts: 7167
Joined: Apr 14 2007 11:37am
Location: Dallas, Texas. U.S.A.

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by Drunkskunk » Jun 22 2015 11:48am

Very cool! looks like it's going to be an amazing build!
Buy the ticket, take the ride.
Monster Bike:http://endless-sphere.com/forums/viewto ... =6&t=38667

maydaverave   10 kW

10 kW
Posts: 540
Joined: Jan 13 2009 11:14pm

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by maydaverave » Jun 22 2015 1:26pm

Very nice I have been considering a similar build. Thanks for the inspiration.
e-bikekit 50v 9.2ah cellman pack

User avatar
Sean9002   1 kW

1 kW
Posts: 345
Joined: Jun 16 2013 7:57am
Location: Australia

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by Sean9002 » Jun 22 2015 6:32pm

Gorgeous! Nice to see some aesthetics being worked on too, not just a big ol' mess of wire and batteries like so many builds. :roll:
OSET 20+ - Custom frame and swingarm, Motorims - 66V
Ruff Cycles Porucho - MXUS 3000w - whitewalls - Gloss black/Pearl blue/copper leaf - custom tanks - bobber saddle
Giant Glory 00 - Clyte X5404 - Hubsinks - 18FET Sinewave
Fuji Nevada S - MXUS 35mm- Hubsinks - 12FET Sinewave
39inch longboard Dual 50mm, 12s lipo

User avatar
100volts+   10 kW

10 kW
Posts: 722
Joined: Nov 20 2012 10:05pm
Location: Houston

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by 100volts+ » Jun 22 2015 7:41pm

subscribed
http://endless-sphere.com/forums/viewto ... =1&t=57440

Unlike puppets we have the possibility of stopping in our movements,
looking up and perceiving the machinery by which we have been moved. In this
act lies the first steps towards freedom. - PETER BERGER Sociologist

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by puchwudi » Jun 23 2015 1:54am

Good morning folks!

Thanks for your compliments! I am really happy to get such a nice feedback :)

@Sean9002: I am trying my best :lol:
@100volts+: Thank you, hope you enjoy it!

About one week ago, I got a nice offer from "spinningmagnets". He wants to publish my project on "electricbike.com"...MAN that was a surprise! :mrgreen:

Updating new stuff tomorrow ;)

User avatar
agniusm   10 MW

10 MW
Posts: 2361
Joined: Apr 16 2011 3:06pm
Location: Lithuania, Zarasai
Contact:

Re: Puch Maxi (50ccm) Conversion to Electro Maxi

Post by agniusm » Jun 23 2015 6:49am

This is class. I miss builds like this on ES. Too many bag/Velcro/duck tape builds for my taste. At least there are few that you can learn something, take something and use/ implement.
First i thought it will be classic build and when i saw that it will be converted to something off road, wasn't quite sure about it, but now the build is turning out very nice and not "out of place". Good luck mate!

User avatar
louis raaijmakers   100 W

100 W
Posts: 154
Joined: Oct 09 2013 3:22pm

Re: PUCH Maxi electro build (4 offroad use)

Post by louis raaijmakers » Jun 23 2015 2:27pm

Wow nice build!
Cool to see you have the +- the same specs as my ride :) (http://endless-sphere.com/forums/viewto ... =6&t=59104).
I can garanty you that you will have a blast of a ride once it is done.

i will follow it

greetings louis raaijmakers

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Re: PUCH Maxi electro build (4 offroad use)

Post by puchwudi » Jun 24 2015 2:33am

Thanks to all for your nice words!

Yesterday I cut the fiber glas chassis, i am amazed how good my prototypes look! :lol:

Image

The three layers are unbelievable strong and resistant (had no experience with it) i would also say that 3 layers are waaaay to much for a headlamp xD (4mm material thickness). After seperating the two enclosers, I started cutting them out with a multifunction rotary tool.

Image

Image

On the following picture you can see what the seperating wax and paint causes. It creates a thin film between the styropor and the micture of glas fiber + epoxy glue. So I was able to seperate them very smooth.

Image

Image

However! This is how it looks like right now, after cleaning and milling. I put my hand next to it for a size comperison ;)

Image

Do you see the nice structure from the third layer? I dont know what to do with it ... polish or not? The structure could look cool after painting?!?! ... Well I dont know :mrgreen:

CU

speedpower99   10 mW

10 mW
Posts: 29
Joined: May 05 2014 8:29pm
Location: Vancouver Canada

Re: PUCH Maxi electro build (4 offroad use)

Post by speedpower99 » Jun 25 2015 10:26pm

You get some amazing fabricating skills.
Does moped use same size fork head tube 1-1/8, bottom bracket 68/73mm as regular bike?

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Re: PUCH Maxi electro build (4 offroad use)

Post by puchwudi » Jun 26 2015 4:53am

Hej guys! Just want to keep you up to date, right now i will just upload some pics ... I will comment them later ;)

Image

Mounting for the back fork, finally mounted them on the optimal position.

Image

The gear mount had to be adapted so that it doesnt touch the wing arms.

Image

next step was getting the pedals working...

Image

We had to mount a hole for the chain tightener on the right side.

Image

chain always jumped down from the Front gear, so we created a nice diversion on the top and bottom of the swing...

Image

Image

Image

Image

Image

as you can See, the chain is waay too short, i already fixed that, after putting it together, i cycled around 15km with it, without any problems....i know its not the best way ;)

Image

The next shots show the housing if the headway battery pack... We stopped here... I am not happy with that big box (17cm with) ... Thereto more in the next posts

Image

Image

I have been looking for a strong and simple led light for the bike, so I found a nice headlamp with a XML t6 Cree led. Its perfect for my needs :)

Image

Image

Image

Image

Finally mounted the headlamp on my bike, i am happy with it,

finding the right angle for optimal illumination will be done in the next days

Image

Image
Last edited by puchwudi on Jul 05 2015 6:37am, edited 1 time in total.

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Re: PUCH Maxi electro build (4 offroad use)

Post by puchwudi » Jun 26 2015 4:57am

@speedpower99: Yes, your right! ;) THANKS :)

User avatar
louis raaijmakers   100 W

100 W
Posts: 154
Joined: Oct 09 2013 3:22pm

Re: PUCH Maxi electro build (4 offroad use)

Post by louis raaijmakers » Jun 29 2015 10:39am

haha
i had the same problem when i build my bike.. didn't thought about the chain line.
but when you put a free wheel on to the bike in my case a 7 speed the chain will be straight enough and won't need the plastic chain guides.

your build still goes strong!
louis

User avatar
riba2233   1 MW

1 MW
Posts: 1842
Joined: Jun 30 2013 10:23am
Location: Croatia

Re: PUCH Maxi electro build (4 offroad use)

Post by riba2233 » Jun 29 2015 3:47pm

Just a suggestion, use another tires, these are not the best option... I use them and they don't give me enough confidence. They are also very bad in wet conditions.
My electric moped: http://www.evalbum.com/4966

My electric car: http://www.evalbum.com/5364

User avatar
Sean9002   1 kW

1 kW
Posts: 345
Joined: Jun 16 2013 7:57am
Location: Australia

Re: PUCH Maxi electro build (4 offroad use)

Post by Sean9002 » Jun 29 2015 7:01pm

the brown Masking tape grips are so pro! :lol:
OSET 20+ - Custom frame and swingarm, Motorims - 66V
Ruff Cycles Porucho - MXUS 3000w - whitewalls - Gloss black/Pearl blue/copper leaf - custom tanks - bobber saddle
Giant Glory 00 - Clyte X5404 - Hubsinks - 18FET Sinewave
Fuji Nevada S - MXUS 35mm- Hubsinks - 12FET Sinewave
39inch longboard Dual 50mm, 12s lipo

User avatar
puchwudi   10 mW

10 mW
Posts: 34
Joined: Mar 19 2015 8:43am

Re: PUCH Maxi electro build (4 offroad use)

Post by puchwudi » Jul 05 2015 6:45am

@louis raijmakers:The chain works great without any troubles.. I also forgot about the chain line, i was SL concentrated on the wings :P Thanks :)

@riba2233: Why arent you happy with the tires? I like them.. Mine are called sawa sport... Descirbe what you dont like, maybe i have used them for a too short time;)

@sean9002: Thanks a lot! if you want to buy some just contact me :mrgreen: :P They are just for protection ; )

Post Reply