9c/HS35/X5 Norco 125 DJ 100v project

[MadRhino]

...Ive landed on mine...

That is about what I feel could happen, if I was riding the mountain trails with a Lipo backpack: Landing on a mine.

I mean: Severe DH crash (1000$ repair), broken bones and KO (5000$ hospital), Lipo fire backpack while Knocked Out... Priceless

 

[Andje]

yeah no doubt. To be honest i would be more wary riding hard by myself somewhere i wouldn't be found. But i'd still do it.

 

[sn0wchyld]

[youtube]HXMV7K-QUps[/youtube]

Is this vid available somehwere? be nice to see a daytime ride on that thing!
edit.. just found your yt account. That bike is epic.

also
did you match up your packs weak-to-strong when you first got em? it could explain why you got so much drift when you were bulk charging, though it seems less of an issue now...

 

[Andje]

i did not test them. i charged them all to 4.2 and connected them. I balanced every time i charged, and i found that they immediately started going out of balance and over time got worse and worse. If the BM's had kept up it would have been fine, but in the time i had it just wasn't happening. I still don't know exactly why the hyperion keeps them in balance charging them at 48v without balancers.... but there it is.
Thanks for the complement man; I love it for sure, it is everything i dreamed. I am trying to find a 120km/h solution just for fun, but it would take so much power that it would probably be less useful as a commuter. This is a bike that goes almost 100 and can be carried up 4 flights of stairs twice a day . Batts recharge in about 2hrs, range is about 30-70 km depending on speed/riding style. Life is good.

 

[sn0wchyld]

i did not test them. i charged them all to 4.2 and connected them. I balanced every time i charged, and i found that they immediately started going out of balance and over time got worse and worse. If the BM's had kept up it would have been fine, but in the time i had it just wasn't happening. I still don't know exactly why the hyperion keeps them in balance charging them at 48v without balancers.... but there it is.
Thanks for the complement man; I love it for sure, it is everything i dreamed. I am trying to find a 120km/h solution just for fun, but it would take so much power that it would probably be less useful as a commuter. This is a bike that goes almost 100 and can be carried up 4 flights of stairs twice a day . Batts recharge in about 2hrs, range is about 30-70 km depending on speed/riding style. Life is good.

'that it would probably be less useful' - understatement of the century there!! what sort of tires are you using for those speeds?

30-70km is bloody good out of 24s 15ah. im making the switch to 24s soon too (though on a HT motor), should be a blast, though i think ill be force cooling mine soon so i can up the amps some!

does that hyperion give readouts of stuff like cell internal resistance/ individual cell capacity? once you have that info you can match weak cells with stronger ones, so each sub 'paralleled' pack are averaged to be virtually the same, and should stay in closer balance. Maybe not nessasary if you're happy using balanced charge every time, but if you do you might find that with bulk charging the cells don't drift so much...

are you still planning on upgrading the BMs? I'd be interested to know how.

also, be good to see a video of you riding by, rather than POV. Im interested to see that backpack in use...

 

[Andje]

I have put almost 2500 km on 12$ Tioga road slicks, 1.95's. Say what you will, but with 80$ inside the tire in tube, kevlar puncture strip and polly rim tape i feel safer then with 80$ on the outside. I recently went up to Kenda Flames 2.25 and there is for sure a difference; much smoother cushier ride overall, but less efficient as well.
I burnt my HS from heat buildup and it only had cooling holes; i would keep it under 6500 watts continuous for sure.
Yes it does give all those readouts. I could check it all if i cared, but honestly the biggest difference now is that the Hyperion bulk charges the cells evenly. I have no trouble at all and have balance only once since march; the delta on all the cells was under .1v so essentially no biggy.
No i wont be using a bms. I have the tp packs kit but i will save it for some other project.
I will try and get some ride by soon.

 

[Andje]

today i went offroading, was doing 70-80km runs over rough non cut grass areas. it was, in a word awesome, but also very tiring. Like a roller coaster through a park.
It did destroy the true on my wheels through . that will take some work...

 

[sn0wchyld]

today i went offroading, was doing 70-80km runs over rough non cut grass areas. it was, in a word awesome, but also very tiring. Like a roller coaster through a park.
It did destroy the true on my wheels through . that will take some work...

sounds fun mate. what sort of rims are you running? the standard clyte ones?

 

[Andje]

nah, sun rhyno lites. And it turns out i broke one of the ageing clyte spokes, that was why it was so out of true. Replaced with an ebikes.ca one and we are good to go.

 

[Andje]

swapped my rear rim out for a new sun rhyno. I now have all clyte 12 gauge spokes on the freewheel side and then longer 13/14 gauge spokes on the brake side. The dish is not extreme but is still better then what i had before.

The bike is set up perfect right now; i can hammer the throttle off the line as much as i want and i can hold wot all the way to empty or do stop start as much as i want. I get about 30 km out of the bike at stop/start wot of about 90km/h. Anything slower then 70km/h and i get way more range, the sweet spot for efficiency seems to be exactly 68km/h. Cruising at that speed im sure i could get 50-70 km out of the bike. Slower then 50 km/h and i sure that number would go up again. Stopping and starting requires twice as much power over the same distance compared to cruising through lights.

I drained my pack just yesterday down to about 86v resting, as low as i would ever want it, using about 14 ah out of my 100v 15ah. Charging it took 3 hours 20 mins and it took almost exactly 14ah back in. I am exceptionally happy with this; i thought the packs had suffered but apparently they have hardly changed even though i'm on 2500km at this stage.

so for daily commuting i can't see why anyone who weighed 130-200 pounds would need more then this. x5304, 18 fet, 180 phase amps, 80 amps DC, 26" rim with 2.25 inch tires, gets 93-95km/h top speed with 0-60 km/h of about 2-3 seconds. 24s3p lipo battery, Hyperion charger, 3.5 hour recharge time from empty. The motor gets toasty draining the pack from zero with regen and stop/start hard accel, but the pack hits empty before the motor burns every time even in ottawa in record high August temperatures of like 40 C in the sun. In the winter the motor and controller are happier.

I'm going to try and ride it all winter with studded kevlar tires. We shall see... I don't know how feasible it will be. I am constantly losing traction on my front wheel due to the placement of by batteries in my backpack; if i sit back on the seat and accelerate hard i can wheely easily, i at least loose front traction most of the time. If i stand on the pedals or even just lean forward slightly shifting my weight, the bike is perfectly stable with no chance of wheelies, but for sure the front wheel is still losing traction during hard accel. Makes me wonder about the 2wd setups tbh; can't understand them at all accept for offroad slow rock crawling.

 

[Andje]

Haven't posted anything here in quite a while... I road this bike into the ground as my daily rider for 2 seasons. Then in June last summer my apartment burnt down and I lost the batteries but not the bike. It has been unused since then and a total refit is occurring as we speak! I am going to strip it completely, rework the torque arm situation, upgrade the front fork to a dual crown and go Pelican 1300 with 24s3p 20c turnigies 5ah in it on the front fork oatnet style. Probably upgrade front to a hydro brake. I'll redo all the wiring as well.
Both bikes are getting brake lights and full turn signals. I think this will make me feel hugely safer and keep the cops off my back; I've only ever been hassled about my lack of signal lights.
Hopefully this bike will be back up and running within 45 days.
Pics to come!

 

[Andje]

So we ordered 25 Turnigy 5ah 20c batts from the washington warehouse to the Roethel parcel service in ogdensburg, For 5 bucks you can get anything delivered there and held for you. We drove down from Ottawa, crossed the boarder, grabbed the parcel and headed back. 1100 worth of batts meant 150 in import fees (Ontario/Canada). So for a 24s3p battery it was about 700$ Canadian for each of us. For any Canadians ordering LIPO from HobbyKing I highly reccomend this shipping strat over international HK orders. We ordered last thursday and payed about 90 bucks in shipping to have batteries monday. Ordering internationally would have taken ~two months and would have doubled the shipping cost.
Got them home, checked them all. One batt was a Waranty with cells in the 1.07 range. This was ideal; we ordered 25 with the idea one would be a dud and thats exactly what happened. I have a warranty claim set up and anticipate an easy transaction sending it to the seatle warehouse for an rma.
The other 24 were all pretty much at 3.85. Of the 24, 18 took a charge perfectly evenly, 6 had trouble with a single cell staying low, with the greatest difference being about 3.9 vs 4.2. I am balance charging those 6 now, and I hope with a few charge discharge cycles they will even out.

 

[leffex]

Haven't posted anything here in quite a while... I road this bike into the ground as my daily rider for 2 seasons. Then in June last summer my apartment burnt down and I lost the batteries but not the bike.

Sorry about that. It was not the batteries fault? Alot of battery cycles make em greedy and flammable.

Nice to read about your commute and bike and that you are well. Carry on.

I like speed as well however wont feel safe above 70km/h in my estimates my max. 50km/h feels fast even now. You go above that speed commuting dude. Wow!

 

[Andje]

Feels safe to me, stops in 12 feet or so and I've only fallen once going around a tight corner in the rain.
The fire was not the batteries fault, it was a stove wiring problem.

 

[MadRhino]

Sorry for your loss, and for being kept from the pleasures of winter riding.

 

[Andje]

Ok, so all the batts balanced properly, I'll watch them for self discharge and then run a few cycles with discharge curves from my hyperion and match them by capacity.
I think I've finally finished most of the part ordering. Shocks, Pelican box, front rim, controller, running lights, contactor, and the assorted bits to attach them together. I decided I'd jump on one of zombiesss 24 fet overbuilt monsters with 4110's, so that will be a direct upgrade to my 18 fet that I beefed up. I'm passing that to a friend that is doing his own build.
All told I'm up to about 1500 bucks to refit this thing. It adds up so quick . Still ned to place an ebike.ca order for a new ebrake and throttle.

 

[Andje]

Got the pelican 1200 today. It DOES fit 24s3p of 20c 5ah lipo. Even when i looked at it it didn't look like it would fit 12 bricks but it does . I can really see this whole thing coming together. Just need the shocks to really start building.

 

[Andje]

Got the weight clamps today. Sadly I am worried they are too large. They are clearly larger then the ones Oatnet used, and I know his were all ready restricting the turning radius of his bike. I may or may not be able to come up with a solution once I get the forks too see about the clearance.

 

[Andje]

Seems like the clamps will work. Got the forks and the controller today, as well as assorted throttle bits and contactor. The pile of parts is vast, but will soon dwindle...

 

[sn0wchyld]

damn man... that controller looks bigger than my battery case!! ever thought of doing porno? :wink:

 

[Andje]

I'll get some video for you when it's all put together don't worry .

Got the box mounted today. But my cell phone camera is screwing around so you can't see it .

 

[Andje]

Did some wiring work today. Mounted the controller. I need to get my handlebar riser before I can start permanently finishing components. But the thing is going to come together fast; I need to figure out how im going to externalise the balancing wires. I guess db28 connector is easiest, just need to source one. Until then I guess I can probably live with opening the case.

 

[Andje]

db 37 connectors ordered. some more wiring and battery capacity testing but not much got done today.

 

[Andje]

Almost all the parts are in, enough that I can get it running for tmrw. Pictures to come

 

[Andje]

Bike ran today, if only briefly for the sake of hall verification. CA powers up and measures voltage but nothing else so far... gonna have to redo the wiring i suspect.