Building a custom e-bike frame

[12p3phPMDC]

Great job on that notcher Hal!

Mutch nicer than the Drill press/hole saw setups.

Did you make different rollers for different diameter tubing?

 

[MitchJi]

Hi Hal,

The image link is broken:

I think this is it:

This is a swingarm for new frame. I will make only 2 of them. It will have schlumpf high speed drive (only two speeds; 1:1,5 and 1:3,8 shifted with a heel...), 200mm travel back and front . 200A kelly, custom made water cooled hub motor. The chain is inside right part of swingarm. Left side will look the same but lower tube will be for coolant pipes and upper tube wil be "fiiled" with motor wires and breake hose. The kevlar canopy will be 2cm wider to hold 50 headway cells. 48 for 72v/20Ah and 2 for lamps...
I will try to update this one more often...

 

[patrickza]

300x150x100mm or 300x150x120 with extra wide canopy.Two times and 230x150x100(120)mm where controller is.
I have at home some 20 and 15Ah and will try to arrange...
I 'll let you know.

Hmm, here are the sizes according to cell_man:
Capacity: 20Ah
Size: 227mm x 166mm x 7mm
Weight: 480g

Capacity: 15Ah
Size: 211mm x 150mm 6.8mm
Weight: 400g

So it looks like I could do a 112.2v15ah (34s) pack in this frame for a total of 1.7kwh, that would most likely be plenty but a little more width (20mm) and a 130mm deep (IMHO the max for normal pedaling) area would be good enough for the 36s of 20ah cells which is what I'd really like. The standard stealth bomber has 76.8v20ah for 1.5kwh, so it would be easy to beat that, even te 34s15ah cells do, but a 36s20ah pack would be 2.4kwh and only weigh 17.3kg and give motorcycle performance with a $1800 battery pack... Throw in one of the new collosus motors and you have an incredible ebike/emotorcycle! If you build it they will come HAL!

 

[HAL9000v2.0]

I manage to squize 20Ah to 155mm with and it is still few mm to wide. 15Ah goes with no problem.
I found out that 15Ah are 7,1mm thick and 20Ah 7,6mm thick. I measured 10 cells together then devide with 10.

Under wider canopy(120mm) goes 32x 15Ah cells or 48x headways

 

[es2150]

sorry if this sounds silly, anyway is this the same bike as the stealth bike. I really like the integrated batteries.

 

[johnrobholmes]

No no, this is Hal's bike.

Your fabrication and planning give me much to aspire to! Will the swingarm be monocoque?

 

[cell_man]

I manage to squize 20Ah to 155mm with and it is still few mm to wide. 15Ah goes with no problem.
I found out that 15Ah are 7,1mm thick and 20Ah 7,6mm thick. I measured 10 cells together then devide with 10.

Under wider canopy(120mm) goes 32x 15Ah cells or 48x headways

15Ah cell:
View attachment 2

20Ah cell


16S stack of 15Ah cells


I've only sent 6pcs of the 15Ah cell to Crodriver in Croatia and lots of 20Ah.