Build my own e-bike

[leonardo]

It came! Just went on the first run
HOLY SHIT THAT WAS FUN

Hurry up and get your throttle!

Congrats!
Have you gained some more speed or torque? Please post a movie to make me jealous
I am still waiting for the throttle...

 

[ManoisEscobar]

Hahaha I'll see if my room mate lets me borrow his GoPro. I can't get over how much fun it is. So practical too. I got to uni in 9 minutes this morning compared to the usual 30 by bus. Then did 2 separate trips to the electronics shop for a box to hide the wires:

Everyone that tries it ends up with a huge shit-eating grin on their face.
The power level is great for getting around town. Averaging around 25km/h including slowing down for turns, but I generally putt along around 35km/h while still pedaling.
In short it's ridiculously awesome and fun. Best $590 ever spent.

How are you coming along? I wanna see a pic of everything put together minus only the throttle.

 

[leonardo]

The postman always rings once... not twice. I do not give him a chance to ring the bell a second time! :-D
When some new e-bike parts should be arriving I usually run to the door!
The throttle is here. Finally I can make my first setup!

 

[leonardo]

First thing to do is connecting the several parts. How hard can it be?
Well... after figuring out what needs to be be connected to what, I found out that all components use different connectors.
No standards here. Lyen's controller uses a different connector to the battery. The battery has a huge anderson powerpole connector.
Way to big for the small cables coming out of the controller. Damn...
Replace the controllers cables seems no option, there is no room for cables that big. So how to connect these small cables properly to this huge connector?

 

[leonardo]

That bike is already gorgeous even if it is not yet equipped with electrical parts. I am pretty sure that it will look better if it has the controller and the batteries already. I wish you good luck on this project. You can also make it an e-bike that can be convertible anytime. I guess that will make it better.

Thanks.
Convertible... I did not think of that yet. The Crystalyte hub motor HT3525 is not running smooth wthout power. For making it convertible I will probably need a second rear wheel without hub motor.

 

[leonardo]

Now the time is there to connect all components together, it is wise to now for sure that you do the right thing.
Once more Edward Lyen helps out: http://endless-sphere.com/forums/viewtopic.php?f=31&t=20413
I ordered one of this funny looking testers. Maybe these things come from China originally. :wink:

Found our how to connect the 12 fet Lyen controller to the Crystalyte HT3525 motor, thanks to this forum once again.
Controller > motor

HALLS
Black to black
red to red
Y >Y
G>B
B>G

PHASE
Y>B
G>G
B>Y

 

[Allex]

About the connectors, I usually convert all to 4mm bullets
http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=9283
Or you can just solder your controller cables in to the Andersson tabs above. But that Andersson connector is way to big for your power...takes to much space.

 

[leonardo]

About the connectors, I usually convert all to 4mm bullets
http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=9283
Or you can just solder your controller cables in to the Andersson tabs above. But that Andersson connector is way to big for your power...takes to much space.

This connector came with the 72V battery. Allex, you are right, it is very bulky.
What voltage do you have on your e-bike using these bullets?

 

[Allex]

I tried them in stealth bomber 20s lipo and pushing 70amps they are fine! heard that they are good for around 90amps.

 

[leonardo]

Today I found the e-bike sacko sold one month ago. I looks very much like what I am building right now.
24s Lipo + HT3525 Kraken 41mph - UK: http://endless-sphere.com/forums/viewtopic.php?f=31&t=50705
Looks very nice, the specs and the color are about the same.

 

[leonardo]

I decided to keep the Anderson powerpoles attached to the Crystalyte hub motor and solder matching plugs to the Lyen controller.
There are a lot of posts on the internet about how to do this properly. Most important are: to make a good connection, no loose copper wires outside the connectors and no solder blobs on the connectors.
So, I think I did a nice job soldering the connectors.


Switched the blue and yellow phase wires.

 

[leonardo]

All those wires coming out of the controller...
Pick the right one, do not mess up.
Feels like this guy

 

[leonardo]

Soldered the controller hall wires to the mini XLR connector.

 

[leonardo]

Connected the throttle, the hubmotor and battery to the controller and tried the setup for the first time!

IT WORKED LIKE A CHARM! YEAH!!!!

No hickups from the motor, no hot wires, no overheated controller. Just a smooth test.
This feels VERY GOOD! IT IS WORKING!

 

[hjns]

HI Leonardo,

Hartstikke goed man.

Now show us some pics of the complete bike. Did you think about ebrakes?
Btw, you can buy 210mm brake rotors....

 

[leonardo]

HI Leonardo,

Hartstikke goed man.

Dank je. Je spreekt Nederlands. Ben je van oorsprong Nederlander?

Now show us some pics of the complete bike. Did you think about ebrakes?
Btw, you can buy 210mm brake rotors....

Well, I have only tested the setup. As a proof of concept. I wanted to be sure all is working fine before assembling everything.
I will show more pictures of every step in progress.

210 mm brake rotors. Damn. Too late. I guess my 203 mm discs will do fine. If not, I will look for bigger ones.
Do you have a link where to find these 210 mm rotors?

 

[hjns]

Yep, Nelderlander ge-emigreerd naar Zwitserland.

I found my 210mm rotors on Ebay here. Bit expensive though: 34 Euro.

 

[leonardo]

The mailman ringed only once again.
Today he brought two packages.
One from EVWORKSLAB: a controllerplate to mount the controller to the frame and a torque arm.
And from Edward Lyen: a motor timing device.

 

[leonardo]

My five year old son's bike, gasoline free. :-D

 

[tomtom123]

Damn by the title of this post, I thought you were going to create your own frame like someone else on here did and also create a motor from scratch. I am disappoint. But its a nice bike though. I wished I had that much money to spend.
However I will say that I've seen many people on this forum and on YouTube go 45mph on much cheaper kits like yescomusa kit and on Walmart bikes so Idk if I want to spent that much more just to reach the 50 mph threshold

 

[Bill Nye the science guy]

the beauty is in the high end parts. looks great

 

[leonardo]

Damn by the title of this post, I thought you were going to create your own frame like someone else on here did and also create a motor from scratch. I am disappoint. But its a nice bike though. I wished I had that much money to spend.
However I will say that I've seen many people on this forum and on YouTube go 45mph on much cheaper kits like yescomusa kit and on Walmart bikes so Idk if I want to spent that much more just to reach the 50 mph threshold

Perhaps I should rename the title to 'Build my own component-based-bike'
My main goal here is to have fun building an e-bike using the skills I have. I have no skills as a frame builder.
Furthermore, I am not trying to make the bike as cheap as possible. Just looking for the best components I can afford. Sometimes I have to save money for this project too, just like the rest of us.

 

[leonardo]

the beauty is in the high end parts. looks great

Thanks

 

[tomtom123]

Damn by the title of this post, I thought you were going to create your own frame like someone else on here did and also create a motor from scratch. I am disappoint. But its a nice bike though. I wished I had that much money to spend.
However I will say that I've seen many people on this forum and on YouTube go 45mph on much cheaper kits like yescomusa kit and on Walmart bikes so Idk if I want to spent that much more just to reach the 50 mph threshold

Perhaps I should rename the title to 'Build my own component-based-bike'
My main goal here is to have fun building an e-bike using the skills I have. I have no skills as a frame builder.
Furthermore, I am not trying to make the bike as cheap as possible. Just looking for the best components I can afford. Sometimes I have to save money for this project too, just like the rest of us.

i might sell my TV and old game consoles just to build a bike like that cause honestly i haven't watched TV in many many years and haven't play video games in years either. It's funny cause i thought i would never get sick of video games but i did. Not sure if it's cause i grew up or games got shitty, i'm pretty sure it's mainly cause video games got shitty cause i still enjoy old school video games.

Anyone, you think with a $1,200 budget, i can build a bike like yours? also i can't find this pdf "how to build a 50 mph". I only found a site that wants $40 for it lol. is the pdf free?

 

[leonardo]

I found the pdf for free and I am very surprised he wants $40 for it. That is weird, since all the information (and more) can be found on the internet too. This forum is an example of it.