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  1. E

    electrifying a cannondale bad boy 700

    thanks! - sanding/polishing (ATTENTION here, protect yourself! The dust is dangerous.) - primer - finish (this was some expensive two component finish especially designed for sailplane finishing (low weight because of high covering power, ultra durable) I hade no airbrush so I used a roller...
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    electrifying a cannondale bad boy 700

    Sorry my late answer. No cracks have appeared. The bicycle endured a couple of falls/crashes but on low velocity which I believe were stronger stress tests of the construction than a potential bending of the frame. I believe also that you can't call the mounting completely rigid, as the holes I...
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    electrifying a cannondale bad boy 700

  4. E

    electrifying a cannondale bad boy 700

    that's a good idea. you have to work very precisely and cover the spokes with tape or something so the epoxy will not get into them I think. and maybe if you want to open a triangle form you probably have to split the zippers in two parts other than going around a curve while at the third side...
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    electrifying a cannondale bad boy 700

    Yes I did so after replacing the blown controller with an infineon. I then also connected another low current switch in parallel on the outside for just turning off the bike when I am on a "safe" place. I mean if no thieves are around... the first setup was kind of childish letting flow all the...
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    electrifying a cannondale bad boy 700

    problem with that key is that every farmer could take a ride on your bike :D :D :D just kidding.
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    electrifying a cannondale bad boy 700

    yeah that's why my lock barrel just pushes an on-off push button and then goes back and the keys go back in the pocket where they belong... :)
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    electrifying a cannondale bad boy 700

    I can't get to my controller without key... the barrel also locks my battery box. So that's not gonna happen. But also I will not have a second chance to start loosing my keychain... But anyway, I did it that way. Got in the controller and soldered wires for a parrallel switch. If it happens...
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    electrifying a cannondale bad boy 700

    thanks for the kind words! cheers boris
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    electrifying a cannondale bad boy 700

    thanks dnmun for the quick answer. I got my controller from ebikes.ca. there is no small red wire coming out from the controller. But: there is a switch on the controller itself. I will have to open the controller but I assume that this switch is exactly wired like you suggest: that would...
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    electrifying a cannondale bad boy 700

    for those who want to take a look at the switch... :) My rude opening doesn't make look it better...
  12. E

    electrifying a cannondale bad boy 700

    UPDATE: I burned two mosfets of my ezee controller while dragging my two kid uphill. Got a new 25A Infineon. System works again. But I need a better solution for the power switch. the contacts of my cheap switch behind my lock also did not survived the "accident". Amberwolf pointed me at a...
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    What are people doing to disconnect the battery

    Yes that's what I understood so far. for clearance. here my old switch setup: I knew this was the weakest part of my system. But I had not much choice with my lock system that also locks my battery box with the barrel in open position.... I now understand also why I had problems shutting...
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    What are people doing to disconnect the battery

    ah ok I see. By installing a EV200 Kilovac in my system I also could use an second kill switch on the outer side of my case right that also do not have to be high-current switch (also connected to the EV200). that would be great. Till now I did not have a emergency switch. now afer this happend...
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    What are people doing to disconnect the battery

    thanks amberwolf for the quick answer. if you have seen my design you understand why I have to go for such a solution. that could be solved by an exterior real "kill switch" mounted on my batterie box (on the ground wire between the mosfet and the battery). this I could use to completly shut...
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    What are people doing to disconnect the battery

    credit goes to christian from this german forum: http://www.pedelecforum.de/forum/showthread.php?t=3880 it's based on a simplier switch designed by Segafredo: http://www.pedelecforum.de/forum/showpost.php?p=38433&postcount=5 what do you folks think of it? This allows to use a tiny switch and...
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    One Cat Just Leads to Another.

    looks great! waiting for more pics and mounting.
  18. E

    electrifying a cannondale bad boy 700

    UPDATE. after just about 200 km my thumb throttle broke while pushing it down. no road irregularity, no brute force. fatigue of (cheap) material. instead of getting a new one from canada or somewhere else I managed to repair it using some stuff lying around. it now features a steal core... 8)...
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    electrifying a cannondale bad boy 700

    ok understand now. maybe you could just drive some long enough nails into the side to prevent any shifting.
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    electrifying a cannondale bad boy 700

    I'm not sure if it is my English but that one I do not understand... :?:
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    electrifying a cannondale bad boy 700

    yeah, go for it guys! in winter it's harder to get the epoxy cured for non professional equipped people like we are (using probably natural ventilation). be careful with the vapors.
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    electrifying a cannondale bad boy 700

    maybe those pics will help you. the 9 speed freewheel I got also from ebikes.ca. there's also a technical drawing with the dimensions of the rear eZee hub: http://www.ebikes.ca/store/diagrams/MeZeeR.pdf cheers
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    electrifying a cannondale bad boy 700

    of course I don't mind. :D
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    electrifying a cannondale bad boy 700

    something like that: http://www.hig-hannover.de/html/avdel/blindnietm/dla.htm my dealer said he will put in original cannondale inserts.. whatever. the holes were drilled with an 7.5mm drill I think. Maybe 8.5mm, can't remember.
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    electrifying a cannondale bad boy 700

    Beside the four drink holder holes I had my bike shop drill two additional holes at the top tube and place inserts in it. The box then was mounted with screws from the inside using hard plastic spacers between frame and box. No way to dismount the box without my key or brute force...
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