Black Arrow's ebike update with pictures!

[Ariane]

This is my winter project,

I always liked the Stealth ebike (which a source of inspiration) I find this e-bike clean, elegant and supposedly really fast but I wanted more power, more speed and more range. That is why I’ve had the idea of building my own custom made ebike. As most people know, the heart of any electric ebike his the battery pack so my first objective was to build an ebike around it. I’ve built the frame around the pack to maximise weight distribution.

This e-bike uses a Methods controller (100V 100A) which is software-limited at 65 amps and I run this configuration as 24S 14P (100 Volt 20 Amps total). I used 24" wheels with an X5304 motor with front and rear 9" rotor hydraulic Hayes Strokker breaks.

Ordinary bike forks being out of price, I have used an old CR80R rebuilt fork. Although this fork is not the lightest one on Earth, an equivalent fork in the bike department would have cost upwards of 1500$ Mine is stiffer and is perfectly adapted for my ebike. The frame and the swing arm are made of steel which is easy to fix and cheap to work with.

I also used a large Cycle Analyst display but I need to design a better case for it (everything is working fine) I will equip the bike with (2) 900 lumens flashlight (P7-C) and I will use a DC-DC transformer to power the lights. In the future I will also need a chain tensioner to remove the derailleur which is useless on this ebike and i need a kick stand :lol: .

Black Arrow

 

[gwhy!]

Hi BA,
Your bike looks cool , what form of steel did you use to make the main frame ( tube or angle )? what was the layout of your main frame and what sort of weight did it come out at if I may ask.

 

[Ariane]

Hi gwhy,

I used angled iron steel but a steel tube would have been preferable. For the layout of the bike, I first installed the 24 " wheel of the CR80 fork then I put the rear wheel into the swing arm, thirdly I built the battery pack. Then I arranged all those components flat on the ground, the wheels leaning against a wall and I had fun finding the correct angles for the ebike with this battery pack in the future frame.

After that I have made a full-size cardboard mock-up to get an idea of the final result, I do not know what the exact weight of the bike is but according to my estimates it's about 125 lbs.

Good day!
Black Arrow

 

[gwhy!]

Thanks BA,
I'm thinking along the lines of a similar design for my first home built frame using angle but wasn't to sure how rigid it will be ( so I'm guessing its not to bad ) . Up to now all I have done as regards welding is putting metal blobs onto other bits of metal but I have been practising and its getting a lot better I invested in one of those automatic welding mask and this have improved my welding 100% so I think I'm ready to have a crack at a bike frame.

 

[Doctorbass]

Hey Bruno, i'm very impressed by that build!!
It look very nice and strong!

it's like a DIY Stealth Bomber made .... in ... QUEBEC !!!

Congrat!... I would appreciate having time to build mine too!

I need time!.. i'm too Busy!

Doc

 

[drewdiller]

Awesome!!

What size tires are you using? I want to build a an electric Pugsley for winter riding, but I also want suspension, which means I'd have to literally build one as you have.

For kick stands, I'm going to get one of these, I read too many "they're flimsy!" sort of reviews regarding dual kickstands that stow to the left side.

http://www.click-stand.com/

It's like a tent spine with a U shaped cradle.

 

[doc007]

it looks like you achieved your goal! Got any pics of the insides?

 

[John in CR]

Great job Black Arrow! Come on, we all want to see the guts, so where are the interim construction pics?

 

[Ariane]

Hey Bruno, i'm very impressed by that build!!
It look very nice and strong!

it's like a DIY Stealth Bomber made .... in ... QUEBEC !!!

Congrat!... I would appreciate having time to build mine too!

I need time!.. i'm too Busy!

Doc

Thanks Doc,

Comments are really appreciate, and guess what i hope you can try this ebike this summer. I know that you are busy my friend, but remember Doc in back to the future is always busy with many project in mind, then your nick really fits you. :wink:

I still have the full-size cardboard mock-up if you need's it, good night and take care Doc
Black Arrow

 

[Ariane]

Awesome!!

What size tires are you using?

Hi Drew,

Thanks for your words and for the link about the kick stand but i think that i will design my own kick stand because my ebike is too heavy. The tires are from Vee-rubber 2.6" wide model "Stout".

Good day!
Black Arrow

 

[Ariane]

it looks like you achieved your goal! Got any pics of the insides?

Hi Doc007,

I don't have any pictures on the inside for now but when it will finish i'm going back with pictures off the inside, i promise

Good day!
Black Arrow

 

[Ariane]

Great job Black Arrow! Come on, we all want to see the guts, so where are the interim construction pics?

Thanks John,

Nice to see you, by the way i have seen your videos and is really cool to see you riding with LFP. I will send the construction pictures later i need to put them in order but for now my priority is to finish the ebike and testing it, is the fun part of the desing

Good Day!
Black Arrow

 

[patrickza]

Fantastic build, I've been waiting to see this for some time now. You've pulled it off even better than I imagined! What is the battery box width you're using? I'm also keen to see how you attached the motor to the frame.

Are you sure you want to remove the derailler though? I know you don't need it as long as you have power, but gears are quite useful when you unexpectedly run out, or if some other bug creeps into the system far from home...

 

[Ariane]

Hi Patrick,

Thank you for your words, I really appreciate it, the width of the ebike is 3.5" I have used the length of a regular 18650 Konion's. I have wrap the cells in the horizontal position. With a first layer of electrical tape around it, a second layer a think plastic sheet and third layer of heat shrink to complete the pack. The (2) battery pack can be switched in about 5 minutes by removing the 6 screws that hold the right cover.

I have posted (with this reply) 2 pictures of the open drop out. I will finally keep the derailleur and i will have a two stage reduction gear mount on the swing arm pivot for pedaling the ebike from 0 Kph to about 60 KPh. (Which I can also use it if something goes wrong with the electrical side.)

Good day!
Black Arrow

 

[Ariane]

Hi Guys,

I have done many updates on my ebike since I have post the first pictures here. Now I use Shimano Saint Calliper those brake are more powerful than my Hayes Strokker ryde (front brake) with a 9” rotor with better modulation.

I have changed the pedal for the Crank Brother eggs beater I love them some people love them and some other not.

I have also change the tire for the narrow Vee-Rubber Stout at 2.3” it’s give me better cornering, less noise on paved road and when I ride in the sand it’s doesn’t seem to make any difference then my previous set up and never get back with 2.7”.

I use (2) 900 Lumens Led flashlight for lighting and I have keep the original (3) mode function then I have High mode, Low mode and flash mode. I the next future my plan is to make a video at night with those light.

The controller on the bike is Lyen editions with 18 fets 4310 I have done the modification for 90 Volt regen modification and I have beefier the trace without any modification on the shunt with the CHXS program this controller rock’s now.

Enough talking and place to the pictures, good day!
Black Arrow

 

[Doctorbass]

Wow.. That really rock!!!

I hope we will be able to ride our ebike together this summer in july !!

Me to i appreciate alot the modification that CHXS done on the new controller program !!

Doc

 

[Ariane]

Hi Doc,

Yes I hope, it will be fun and I’m impatient to see your new ebike with Lip, it will be fun to ride with CHXS also if he can and i bring my camera this time to make some videos.

Good day and I have nice week-end my friend!
Black Arrow

 

[deecanio]

nice bike BA!!!
im curios brother, what did you do with the mongoose??

D

 

[Ariane]

Hi D,

Nice to see you, this first edition of the mongoose:



The second edition:



With the third edition i have sell the Agni motor to Ypedal with the controller Alltrax 7245 and i have use the steer tube of the mongoose on this new bike. There’s nothing left about the frame of the mongoose except this part and this original 450 watts motors.

Good and take care D
Black Arrow

 

[deecanio]

Hi BA,

thats a shame, im still hoping to pick up a cx at some point and was going to ask if i could buy your old frame.
Not to worry, anyway im hoping you shoot some video for us all at some point, would be nice if you meet with DocBass again and get it on film.
good day BA, take care.

D

 

[Ariane]

Hi Deecanio,

May be not a shame at all :lol: , my old frame as made is time I mean that it as bean cut and weld too many times. I forgot to mention that I have also reused the bottom tube with the sleeve (this tube serves to keep the swing arm in place in my new ebike and on second edition).

If you need a good frame is better to start from scratch and build your own frame base on this mongoose design, this frame as nothing special and is not very hard to make one from the scratch with the right dimension for your needs, Others members here, with this Mongoose frame are TylerDurden, Joepostal and Duffmanaudio to name a few.

Good Day "D"
Black Arrow

 

[bandaro]

sweet ride man, how has it been going? still going strong?

i had a question regarding the width, how wide is it now and is it too wide or could it be wider?

 

[Ariane]

Hi Bandaro,

My ebike is very strong; the wheel base is 53.5" and the handling is really great compare to any DH bike and the carving is really great with the correct tire.

This ebike is wider enough, the internal width of the frame is 3 ½ "and about 3 ¾ for the external. Of course it can be wider, but one of my primary goals was to be able to pedalling it and I wasn't able to do it with a wider frame.

Presently the weakness point on my ebike is my batteries pack I think that those Konions are getting weak on every ride. I'm trying to figure if I can put a Lipo pack at 100 Volt 25 Amps on this frame.

If I had known that Motopeds exist, I will never create my own frame and i use the Motopeds frame to build my own ebike.

Good day!
Black Arrow

 

[torker]

Always loved your builds BA I saved the pics of version 3 Would love to recreate that.. Also like the one piece cast crank- We don't really need no stinking pedals Keep up the great work and be safe. ps I would like to see a closer shot of the flashlight mounting and maybe a shot or explan. of the swingarm pivot..

 

[Whiplash]

Cool build! We need video of it in action!