72v 6kw Custom Build

[not.py]

Welcome, here i will be posting progress updates and the story of my bike.

To start, about a year ago i picked up the whole frame (Giant xtc sx), wheels, suspention, ect for ~£10.

I had to cut the frame to get the seat to sit lower and design a custom metal bottom bracket replacement for my pegs on the lathe as the bike didn't come with one.

Bought the kit (MXUS 3k turbo 3t 26", 80a unbranded china controller, ukc1 display, ect) for ~£600 and a 72v 30ah (80a continuous discharge) triangle battery for ~£600 as well.

(yes i know the leds are goofy, they are gone now)

Bike wasn't too bad but was lacking in top speed (50 - 55mph) and i wanted regen.

After discussing with the sales director (lvchao@far-driver.com) at fardriver i decided on a ND72360.
The controller costed:



Once the fardriver arrived i made a custom metal mount for it and ziptied it (just incase). Tuning it wasn't too bad, took a few youtube videos but it's easy.

After the bike was running with the new controller i added a fuse board for accessories and swapped out my old 125A breaker with a fuse and switch aswell as remaking my precharge circuit.


Definitely not the cleanest of bags but it's functional!
I have a temp sensor on the custom aluminium plate connecting the fuse and the switch just incase there's a bad connection anywhere.

The T connector mentioned is:

Keeps everything modular and allows me to easily bypass the whole system if there is a issue.

Also added a crf50 (motorbike) seat recently for comfort, Here is the underneath showing how it's attached to a seat post.

Seat has held up so far other than creaking and is a lot more comfortable than the average bike seat.


Here is the bike currently,

Who cares about looks when you have power
Future plans:
Im currently using my phone and the GDriver app as a display but in the future i plan to make my own custom app and find/make a better holder.

I also plan on adding side panels to enclose everything super neat. This will also give me better mounting options for switches, chargers buttons ect (i'm running out of handlebar space).
I'm going to extend my forks so they are fake dual crown ones so i can mount a KTM front light and mudguard.

Waiting on a rear mudguard that will attach directly to the seat at the moment, i think it'll look a little better then.


Thanks for reading, feel free to give criticism below. Always looking to improve.

 

[99t4]

Seat has held up so far other than creaking and is a lot more comfortable than the average bike seat.

That's because the "average bike seat" is designed for better comfort while pedaling. To minimize chafing of the inner upper thighs through the legs pedaling motions. On a pedal bike that seat would not be so comfortable.

 

[slaphappygamer]

Could you elaborate on your switch?

I have a key switch/voltage readout combo, but I installed it between the controller and display. I was thinking that a switch, between the battery and controller, would take the current requested by the controller.

 

[not.py]

Could you elaborate on your switch?

I have a key switch/voltage readout combo, but I installed it between the controller and display. I was thinking that a switch, between the battery and controller, would take the current requested by the controller.

I have the same volt meter and key, mine is wired to the controllers ignition input.

In the bag i have my main high voltage switch setup,

Parts are below:
Switch: https://a.aliexpress.com/_EybK79C
Fuse (I'm using the 125A): https://a.aliexpress.com/_EwbFIp8
Button (precharge): https://a.aliexpress.com/_EuObPF8
Resistor (100w 100r): https://a.aliexpress.com/_Ewza0iO
(Let me know if any of these links are incorrect)

Only spec issue is the switch being 60v instead of 72v but it's not too much of a difference and i haven't had issues.


Hopefully that makes sense, the button for the pre-charge resistor is bypassing the main switch.

Holding the button for ~3s charges the capacitors then you can flick the main battery switch, this prevents the high draw while charging the capacitors.

 

[not.py]

Recent top speed run i did, this is currently the fastest i've been on this bike.

Was done on a straight trail just before it started to get dark (emptiest times with daylight).
Before anyone starts to complain, the trail is straight, highly visible and flat. There is no risk here and it's a lot safer for everyone involved to use a trail instead of a 60mph road)

 

[not.py]

For the phone dashboard display i'm planing to use a phone case like this:

(Metal case that is screwed together)
And attaching handlebar mounts to the back


I want to use a phone as a dashboard as i like the idea of it being multi functional (not only for speed but directions, messages, google ect)

I've messed around with the fardriver bluetooth communication a little but i couldn't get much to work. It's my first time doing bluetooth things so if you have anything useful please feel free to share.


This phone dashboard is heavily taking inspiration from the Stark Varg's phone display.


I did try find the manufacturer of this but i didn't get anywhere and £300 from stark (just for the holder, not even the phone) is quite a bit out of budget.

 

[neptronix]

Happy to see the art of the electric hot rod is not dead in the UK!

 

[not.py]

Happy to see the art of the electric hot rod is not dead in the UK!

It's not too bad where i'm from.
Police are starting to use off-road units now (usually surron ultra bees) in London.


Our ebike laws are strict with anything over 36v 250w pedal assist being illegal and treated the same as a motorbike.

Laws go out the window when you try fit a police suv through a bike gate though!
(This is a joke, don't break the law)

 

[not.py]

I also plan on adding side panels to enclose everything super neat. This will also give me better mounting options for switches, chargers buttons ect (i'm running out of handlebar space).

All good things come from cardboard and tape.

Got some hard plastic sign boards, not exactly sure on what the material is but it's light, strong and easy to cut with a stanley knife.

Need to figure out how i'm going to attach the side panels, i did think of rivnuts but there's enough holes in this frame already and i don't fancy adding 6+ more on each side.

 

[not.py]

Side panels partly done. (There are still a lot of smaller panels to do, trust the process)

I feel like it needs a sort of sub frame look for under the seat. If you have any ideas please draw them thanks.

Here is what i'm thinking with the black being a recess: (whole frame will be painted black in the end, also showing a mudguard and front light)

Huge inspiration being taken from the K5 here.

Base to draw over:

Thanks.

 

[not.py]

Ordered a Raspberry Pi Zero 2W, going to attempt to emulate sounds of a dirtbike with it based off the throttle. This will be easily toggleable to take advantage of sound and quietness.

 

[AGS]

Your bike looks just like my bike.

 

[not.py]

Your bike looks just like my bike.View attachment 373962

Nice bike, mine is going to be less boxy and a bit more shaped out in the end though.

It's also been compared to the Top Gear P45 before:

 

[AGS]

You could go for the Tom Cruise style:

 

[not.py]

Anyone got any idea on why my fardriver pulled 100A+ today?

Controller is tuned to 80A and all of my previous rides have been under 85A.

Wasn't doing any particularly hard riding.


"Max Line Current: 103.25A"

My tune: (There is no boost button)


Off topic, but here is my tune if you'd like to give advise:

(Can't see how to upload videos here)

 

[not.py]

Bike was seized today.

Boxed in at a traffic light by an unmarked XC90 and literally dived at by an armed officer. Luckily no charges against me at all (benefits of not having a driving licence.

Approximately £1000+ being crushed.
While waiting for the tow I managed to cut the bike up to pieces and salvage as much as i was allowed; lights, holders, whole fardriver wiring harness, ect.

This is all that was left for them:

Battery: £600
Controller: £100
Motor: £300
Other Junk: £100

Will make attempts to buy it back from the yard but my local police department doesn't auction seized vehicles.

Only coming back bigger, probably not soon though.

 

[neptronix]

Dang.
Next time you probably want to focus on stealth appearance if you have the guts to go for round 2.
It's easily achievable with some creativity.

To help assess the danger levels for others:
- were you pedaling?
- how fast were you going and approx what was the speed limit?
- what kind of area were you in, residential, downtown, rural, what..

 

[not.py]

Next time you probably want to focus on stealth appearance if you have the guts to go for round 2.
It's easily achievable with some creativity.

To help assess the danger levels for others:
- were you pedaling?
- how fast were you going and approx what was the speed limit?
- what kind of area were you in, residential, downtown, rural, what..

Stopped at a traffic light, they didn't see me moving at all & no pedals. (Also no reports from public about me)

Quiet street ironically a few minutes away from a police station.

Next build will be alot cheaper, planning on making the battery and everything myself so that'll be interesting.
As cringy as it sounds, it's more than a hobby, this is how i get around and enjoy spending my free time.

 

[not.py]

In the UK, if your bike is a "EAPC" (Electric Assisted Pedal Cycle) it is entirely legal to ride on public roads.


(Official gov.uk)

In short:
A legal bike must have a 250w nominal motor, limited to 15.5mph pedal assisted.

It also must:

All easy to display.

The Good Stuff:
In "theory" i could have a 48v+ battery on a modded motor or one with dodgy ratings.
The only holdback for me would be the speed limit but this can always be hooked up to a separate remote switch.

 

[neptronix]

I'm betting the no pedals and very DIY appearance is what got you nicked.

If i was in your area, here'd be my setup:

- the most high density mid drive i can get ( one in pic i've tuned up to 1.5kw )
- the most bike looking possible, and always pedal it.
- throw in a small rear geared motor and hide it with a big disc brake and black gears.
- hide battery and all wiring possible in a bag.

Should be able to get north of 2kw while still looking stealth. Passers by will be focused on the small mid drive, not the small geared hub

OR

You cover some honker of a DD motor with long panniers and also hide everything in the bag.

here's my 'could be stealth, but isn't yet because nobody in my area cares' build:

 

[not.py]

I'm betting the no pedals and very DIY appearance is what got you nicked.

If i was in your area, here'd be my setup:

- the most high density mid drive i can get ( one in pic i've tuned up to 1.5kw )
- the most bike looking possible, and always pedal it.
- throw in a small rear geared motor and hide it with a big disc brake and black gears.
- hide battery and all wiring possible in a bag.

Should be able to get north of 2kw while still looking stealth. Passers by will be focused on the small mid drive, not the small geared hub

OR

You cover some honker of a DD motor with long panniers and also hide everything in the bag.

here's my 'could be stealth, but isn't yet because nobody in my area cares' build:

The officers said they thought it was a surron at first, while this added to it i don't think it was the direct cause.

I've been chased numerous times before on this too:
(48v 2kw)

Usually they chase me while i'm moving, just got unlucky this time being at a red light with an unmarked and not prepared.

My next build will either be pannier heaven or a "legal ebike" look abusing the "loophole" i mentioned previously.

 

[neptronix]

Damn, hunted down on a bike like that?

Man, sounds tough out there, GL and let us know how it goes

 

[scianiac]

Do your police really have nothing better to do? Over here the problem is the police do nothing until there are so many illegal ebikes going around you can't safely walk in some cities, at which point there is public outcry and then they sometimes do something. I'm being a little hyperbolic for comedy but not that much.

 

[TPEHAK]

Could you just flip the bird and ride away? What is the reason of confiscating? He captured you on camera accelerating without cranking the pedals? Did you check your court cases about confiscating the e-bikes? Are you sure the officer acted legally? Can you file a complaint about his actions? You gotta fight for your right.

 

[not.py]

Could you just flip the bird and ride away? What is the reason of confiscating? He captured you on camera accelerating without cranking the pedals? Did you check your court cases about confiscating the e-bikes? Are you sure the officer acted legally? Can you file a complaint about his actions? You gotta fight for your right.

Section 165A of the road traffic act gives officers the rights to seize vehicles being driven with no insurance.

The officer only saw me sat at a traffic light bike off and not moving, i suppose you could try argue i wasn't driving and there's no evidence that i was but given there is no pedals on the bike, it seems a bit silly to be standing at a red light with a ebike turned on and no other way to propel it.

The bike gets crushed in 2 weeks (2 days if they claim it was used anti socially).