Build thread - 26" MTB rear 1kW hub, 72V 1.5kW controller

[ken1645]

First I'd like to thank everyone that posts their knowledge in this forum. It is an amazing source of information. That being said I'm going to share how my build goes along with all my parts list.

1kW 26" 48V rear hub kit
View attachment 8
http://www.yescomusa.com/Brushless_Electric_Bicycle_Engine-_48v_1000w_Rear_Wheel_Hub_Motor_Kit.html

72V 1.5kW Hua Tong 40A controller
http://www.aliexpress.com/item/72V-1500W-Brushless-Speed-Controller-for-Electric-Bikes-High-Quality-OT100/287758466.html

EM3ev triangle battery bag to go inside frame
http://em3ev.com/store/index.php?route=product/product&product_id=125

26" mountain bike - steel frame

http://www.walmart.com/ip/26-Roadmaster-Granite-Peak-Men-s-Mountain-Bike/21191072

8x of 5Ah 5S 20C Turnigy batteries for 20s2p
http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=15008

Thunder 1220 balancing 12s charger

http://www.hobbypartz.com/75p-1220-charger.html

30V 5A DC power supply - edit: This power supply is horrible. DO NOT BUY IT. Get a 500W+ server power supply on eBay
http://www.ebay.com/itm/370586966860?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

Key switch for battery supply (kill switch)

http://www.ebay.com/itm/170655659064?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

Voltmeter
http://www.ebay.com/itm/170846310527?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

4x battery medics. In hind sight I don't think I needed any of these Maybe I'll resell or return them. The Thunder charger balances already...
http://hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=10328

Doc's Torque arms
http://endless-sphere.com/forums/viewtopic.php?f=31&t=29129

I'm also wanting to get a pair of vertical red lights to go along the back but I'm not sure how to get 12V out of my 74V battery pack. The only DC to DC down converters I've found are for 48V down to 12V. How do you guys that run 72+V rig up your lights? Separate batteries??

Will post more once more items arrive and I'm able to start building.

 

[ken1645]

My 72V 1.5kW controller still isn't here yet from China.. Apparently it is in California right now so it is making its way slowly to Texas

In the mean time I went ahead and hooked up the 48V 1kW controller that comes with the yescomusa kit. I've gotten pretty good at soldering 4mm bullet connectors now after a few how to videos on youtube and I got everything hooked up. WOW is it fun! I took a test ride about 5 miles to downtown Houston and back using 15s1p. The batteries were charged to 4.15V each at start and ended up at 3.75V when I got back.

I got up to 36 MPH down a hill on Allen Parkway (Houston). On flat I was going around 30 MPH.

I did discover I can't stop for anything though. The rear V Brake is screwed up and to not get it to run on the rim of the tire I had to make it go out so far that now it can't even do anything as a brake. I've researched how to adjust the brakes and after trying all the adjustments I don't think it will work... so my only brakes are the front brake. Works alright as long as I plan my stops and coast for a while. My 72V controller has regen which will work great as a brake.. I'll be modifying the 72V Hua Tong 40a controller using this thread: http://www.endless-sphere.com/forums/viewtopic.php?p=509239#p509239

The location of the controller is not good I found out as well, it was hot when I got back home. I'll be mounting it somewhere else so it gets air flow. I want to get my triangle battery frame bag... then I can get rid of the cargo bag in the back and mount the controller on the cargo rack.

If the regen isn't enough for braking then I'll be just buying a new bicycle with disk brakes. The frame I have now does not support the things to connect the caliper on to for disk brakes Oh well, it was cheap.

I do like my key ignition switch though pretty sweet.

 

[thechidz]

sub'd. this bike is gonna be monster

 

[ken1645]

I've been busy hacking away at my bike and I think I've got it as far as this frame can go..

I added 2 of these red LED strips on the back to be controlled by the small push button on the thumb throttle http://www.ebay.com/itm/RED-12V-30cm-18-LED-Water-Proof-Flexible-Light-Strip-w-Adhesive-USA-Seller-/181151043648?ViewItem=&vxp=mtr&item=181151043648&nma=true&si=Pi249gh1IaGcK8nnNaRu1km4cUQ%253D&orig_cvip=true&rt=nc&_trksid=p2047675.l2557
Really bright!
View attachment 2

Got my triangle battery bag too. This frame is too small to fit all 8 batteries comfortably so I've been doing 20s1p. I got a new bike with disc brakes and a bigger frame which I'll just make a 2nd ebike out of soon. But here it is for now. Controller on the back cargo rack. Pic taken a while ago while I was building.


Edit: got creative and got all 8 packs in the bag for 20s2p!

 

[ken1645]

Flat tire today on the rear hub motor.. At least it was while I was stopped for a drink and thankfully only 0.5 miles from my place. Going to be getting a new tire & tube as I'm pretty sure there's tons better of both available.

 

[ken1645]

So recently I just hit 300 miles on my eBike. A week ago I had an issue with my regen brakes kicking in randomly at all speeds. I took the controller off and opened it up, looked fine and all connections seemed to be good yet it still would stutter. I discovered somehow my ebrakes which were hooked up to regen had some wires loose; screwed those in and todo bien. Here's some pics. The girl = my girlfriend.

 

[triggeraa]

Great job. What kind of speeds are you getting?

 

[ken1645]

Great job. What kind of speeds are you getting?

40 mph flat. Downhill my max is 46mph. Range of 25 miles, more if I go slow too.