cruddbucket
100 µW
Hi ebike people
Just want to share my bike build which is still in progress.
I was inspired by my Friend Dan, after riding his Demo 9 with TC-80 and 72V 60A controller. We both come from a Downhill riding and racing background. Luckily
the Demo 9 frame is well suited to a conversion and we had them laying around from earlier days.
Here is Dan's conversion:
I contacted Crystalite direct (Kenny) who was very helpful, he sent me a TC80 and 96V 45A controller with 18FETS.
And here is the beginning, stripped down the Demo 9 and gave it a good clean. You may be able to tell just how filthy it was lol.
The motor controller is a good size and fits nicely here:
Most of the components are installed on the bike now. Same as on Dans bike we CNC milled some aluminium adapters to bolt the wheel on. This have held up to 6.5kW abuse for ~1000km. For the moment the axle nuts are simply loc-tited in place, further down the track we will fabricate a lock of some type.
Was a bit of a pain to get the motor going as this is a first time installation for me, it didn't help I was using the CA V3 which doesn't make it very simple either.
Got there in the end however with some help from Dan via Watsapp - he works offshore for 5 weeks at a time so unfortunately he couldn't be present to help. That would have accelerated the process but I sure wouldn't have learnt as much as I did.
Here are some parts I 3D printed for the bike. A regen bracket for the handle bars, and 4 x stanchion clamps for the battery box. This stuff is strong and flexible.
Here is a picture of the battery box installed, I may install a smaller box later but this will do for now. I can fit 6 x 6S 5000mAh packs in there.
Also soldering up the battery leads from box to controller as can be seen draped over the handle bars.
At this stage I was able to ride it around, pretty cool and stoked
Need to calibrate the shunt resistance value though.
Here is a picture after tyres inflated at the local petrol station. Some may dislike the battery box up the bow, but it really helps to balance the weight of the bike front and rear.
Here are 4 x 6S 5000mAh packs in the box. Not what I am going to use but had them handy.
So that is where I am at now!
I still need to wire in the regen button, add a rear sproken, tensioner and chain... and lights front and rear.
But the modifications continue Dan and I have paid for two Adaptto Max-e controllers which are due to be sent early next month.
In the mean time I am considering trying 150V battery supply to this controller or doing a shunt soldering mod. Yolo.
When the Adaptto controllers turn up this one will be sold off.
Hope you enjoy the pics!
Cheers
Luke
Just want to share my bike build which is still in progress.
I was inspired by my Friend Dan, after riding his Demo 9 with TC-80 and 72V 60A controller. We both come from a Downhill riding and racing background. Luckily
the Demo 9 frame is well suited to a conversion and we had them laying around from earlier days.
Here is Dan's conversion:
I contacted Crystalite direct (Kenny) who was very helpful, he sent me a TC80 and 96V 45A controller with 18FETS.
And here is the beginning, stripped down the Demo 9 and gave it a good clean. You may be able to tell just how filthy it was lol.
The motor controller is a good size and fits nicely here:
Most of the components are installed on the bike now. Same as on Dans bike we CNC milled some aluminium adapters to bolt the wheel on. This have held up to 6.5kW abuse for ~1000km. For the moment the axle nuts are simply loc-tited in place, further down the track we will fabricate a lock of some type.
Was a bit of a pain to get the motor going as this is a first time installation for me, it didn't help I was using the CA V3 which doesn't make it very simple either.
Got there in the end however with some help from Dan via Watsapp - he works offshore for 5 weeks at a time so unfortunately he couldn't be present to help. That would have accelerated the process but I sure wouldn't have learnt as much as I did.
Here are some parts I 3D printed for the bike. A regen bracket for the handle bars, and 4 x stanchion clamps for the battery box. This stuff is strong and flexible.
Here is a picture of the battery box installed, I may install a smaller box later but this will do for now. I can fit 6 x 6S 5000mAh packs in there.
Also soldering up the battery leads from box to controller as can be seen draped over the handle bars.
At this stage I was able to ride it around, pretty cool and stoked
Need to calibrate the shunt resistance value though.
Here is a picture after tyres inflated at the local petrol station. Some may dislike the battery box up the bow, but it really helps to balance the weight of the bike front and rear.
Here are 4 x 6S 5000mAh packs in the box. Not what I am going to use but had them handy.
So that is where I am at now!
I still need to wire in the regen button, add a rear sproken, tensioner and chain... and lights front and rear.
But the modifications continue
Dan and I have paid for two Adaptto Max-e controllers which are due to be sent early next month. In the mean time I am considering trying 150V battery supply to this controller or doing a shunt soldering mod. Yolo.
When the Adaptto controllers turn up this one will be sold off.
Hope you enjoy the pics!
Cheers
Luke
