I've had my borg frame for over a year now, so there's no excuse as to why it took me so long to get started. Anyway here was the shopping list:
-The borg frame
-Cromotor in a 24 inch wheel
-Rockshox boxer race. Wanted white but only had black available
-Shlumpf high speed drive
-Lyen 18 fet 4110 controller
-Headways
-Szsmartec BMS. Wanted a headway one but they no longer make one.
-BB7 brakes. I prefer them to hydros
Ok then onto the planning stage. I wanted at least the range and power of the lifepo4 powered stealth, so I had planned on a 48 cell headway pack with 24 going into front area, 24 in lower area and the rest of the electronics in the rear compartment, but alas the borg case wasn't 12.5cm wide as I needed, so I had to use the staggered 3 cell connector blocks instead of the inline 2 cells. This means 48 wouldn't fit as I'd planned. Clearly some cells would have to go in the rear compartment.
According to HAL I should manage 23 + 23 + 2 in the compartments, but that meant splitting a parallel pair, and to be honest I couldn't see how you'd get 23 in the lower section. So 22 + 22 it was going to be, then 4 in the rear. Now putting 4 cells in the rear means that either the BMS or the controller won't fit. I thought it a better idea to keep the controller outside so it would be cooler. I may bump it up from 60A to 100A at some stage, so all the cooling I can get may be helpful.
Making this call freed up some additional space in the the trunk, and I always feel that spaced should be used, so after finding out that the BMS I'd ordered went up to 26s, and that I could easily put another four cells in the back I quickly changed my order.
So, so far I've built all the battery packs and have them on the frame. Now to do all the connections and install the other electronics. I'm probably about half way. Hopefully I get the BMS connections soldered nicely, then build a precharge circiut, figure out the controller and motor combinations (should be colour for colour according to what I've read) and figure out which red wire turns the controller on (http://www.endless-sphere.com/forums/viewtopic.php?f=2&t=45456).
Here's what it looks like now, please ignore the untidyness and duct tape, I'll work on looks later:
That's a lot of blue, the front cover on the left may be a tight squeeze, but I'll hopefully make it work. Can't wait to feel the power of the cro and enjoy the range offered by the borg. 52 headways is 1664 wh of power. I'm hoping to do the 40km to my moms place in under an hour, and using less than 80% of my pack. In a crazy moment I thought of going 3p and building a box in front of the lower battery tray for another 24 cells, but sanity prevailed. For now
So far I think this is an awesome frame. I like range and this one really lets you pack in the cells. I actually think there's room for more. There's miles of space between the front wheel and the frame, and I'd like to see it filled one day. For no particular reason, just because it can. Also without too many changes this frame would be able to handle 32 of the 20AH A123 pouches. Now that would be an amazing bike. Anyway, love to hear some comments, and advice for the rest of the build would be highly appreciated too.
-The borg frame
-Cromotor in a 24 inch wheel
-Rockshox boxer race. Wanted white but only had black available
-Shlumpf high speed drive
-Lyen 18 fet 4110 controller
-Headways
-Szsmartec BMS. Wanted a headway one but they no longer make one.
-BB7 brakes. I prefer them to hydros
Ok then onto the planning stage. I wanted at least the range and power of the lifepo4 powered stealth, so I had planned on a 48 cell headway pack with 24 going into front area, 24 in lower area and the rest of the electronics in the rear compartment, but alas the borg case wasn't 12.5cm wide as I needed, so I had to use the staggered 3 cell connector blocks instead of the inline 2 cells. This means 48 wouldn't fit as I'd planned. Clearly some cells would have to go in the rear compartment.
According to HAL I should manage 23 + 23 + 2 in the compartments, but that meant splitting a parallel pair, and to be honest I couldn't see how you'd get 23 in the lower section. So 22 + 22 it was going to be, then 4 in the rear. Now putting 4 cells in the rear means that either the BMS or the controller won't fit. I thought it a better idea to keep the controller outside so it would be cooler. I may bump it up from 60A to 100A at some stage, so all the cooling I can get may be helpful.
Making this call freed up some additional space in the the trunk, and I always feel that spaced should be used, so after finding out that the BMS I'd ordered went up to 26s, and that I could easily put another four cells in the back I quickly changed my order.
So, so far I've built all the battery packs and have them on the frame. Now to do all the connections and install the other electronics. I'm probably about half way. Hopefully I get the BMS connections soldered nicely, then build a precharge circiut, figure out the controller and motor combinations (should be colour for colour according to what I've read) and figure out which red wire turns the controller on (http://www.endless-sphere.com/forums/viewtopic.php?f=2&t=45456).
Here's what it looks like now, please ignore the untidyness and duct tape, I'll work on looks later:
That's a lot of blue, the front cover on the left may be a tight squeeze, but I'll hopefully make it work. Can't wait to feel the power of the cro and enjoy the range offered by the borg. 52 headways is 1664 wh of power. I'm hoping to do the 40km to my moms place in under an hour, and using less than 80% of my pack. In a crazy moment I thought of going 3p and building a box in front of the lower battery tray for another 24 cells, but sanity prevailed. For now
So far I think this is an awesome frame. I like range and this one really lets you pack in the cells. I actually think there's room for more. There's miles of space between the front wheel and the frame, and I'd like to see it filled one day. For no particular reason, just because it can. Also without too many changes this frame would be able to handle 32 of the 20AH A123 pouches. Now that would be an amazing bike. Anyway, love to hear some comments, and advice for the rest of the build would be highly appreciated too.
