72V 1000–3000W Custom E-Bike Conversion Project – Winter Build (Feedback Welcome)

[Kyzo kits]

Hello everyone,





I’m currently working on a customizable 72V e-bike conversion project and would appreciate some feedback from experienced builders here.





The concept is a configurable system in the range of 1000W up to 3000W, based on a 72V battery setup (25–40Ah depending on customer needs). Target range is approximately 70–100 km depending on riding style and configuration.





Main focus:


• Hub motor solutions


• Matched controller setup


• Clean cable management


• Custom battery integration


• Long-term reliability





The idea is to develop this as a winter build project, so everything is ready for the riding season.





I’m especially interested in opinions regarding:


• Optimal controller pairing for 72V / 3000W setups


• Battery configuration (cell choice & BMS reliability)


• Thermal management at higher sustained loads


• Best practices for safe 72V wiring layouts





This is intended for off-road / private property use only.





Any technical feedback, improvement ideas, or component recommendations are highly appreciated.





Looking forward to your input.

 

[99t4]

• Custom battery integration

What does this mean? Proprietary frame form fitting battery?

You're really asking for a really voluminous time-consuming answer. How much do you know already? What's your experience level? Expertise level?

• Battery configuration (cell choice & BMS reliability)

For this, we need to know more about usage scenario. (speeds, hill steepness and duration, load)

• Thermal management at higher sustained loads

Statorade, more copper in motor.

• Best practices for safe 72V wiring layouts

Drip loops, shrink tubing connections w/ sealant?

This is intended for off-road / private property use only.

What kind of off-road? Fire roads? Singletrack? Hillclimbing?

 

[MxusMick]

Start by reading the "frequently asked questions" in every section, this information is loaded with all of your answers you ask for

 

[OlderGiantFan]

The concept is a configurable system in the range of 1000W up to 3000W, based on a 72V battery setup (25–40Ah depending on customer needs).

Hmmm, sounds like you're looking for a business consultant, what's your budget?

 

[E-HP]

Hello everyone,





I’m currently working on a customizable 72V e-bike conversion project and would appreciate some feedback from experienced builders here.





The concept is a configurable system in the range of 1000W up to 3000W, based on a 72V battery setup (25–40Ah depending on customer needs). Target range is approximately 70–100 km depending on riding style and configuration.





Main focus:


• Hub motor solutions


• Matched controller setup


• Clean cable management


• Custom battery integration


• Long-term reliability





The idea is to develop this as a winter build project, so everything is ready for the riding season.





I’m especially interested in opinions regarding:


• Optimal controller pairing for 72V / 3000W setups


• Battery configuration (cell choice & BMS reliability)


• Thermal management at higher sustained loads


• Best practices for safe 72V wiring layouts





This is intended for off-road / private property use only.





Any technical feedback, improvement ideas, or component recommendations are highly appreciated.





Looking forward to your input.

You might want to post this in the help wanted subforum.