Custom Alu Frame + Cromotor + 2kWh A123 + Kelly Controller

[thinmint]

Hey Guys,

Ive been working on this bike for a while and am nearing completion. Figured some of you may be interested in seeing the progress!
Bit of background; Im an EE undergrad at the University of Florida. I live off campus and own a 600cc sport bike to commute to campus but recently there has been a shortage of motorcycle / scooter parking. Bicycle parking is much more abundant as only students who live on campus take advantage of it.
I love building things, and thought it would be great fun to design an ebike.
I am using 30S A123 20ah pouches from a past project (Electric S2000), a cromotor, and a Kelly 250A 120V brushless controller. Currently working at designing a BMS for the battery pack for the bike as I dont trust chinese BMS manufacturers. Similarly, Kelly controller as Lyen controllers seem to explode left and right.
All work will be done by me using tools I have access to (CNC router, CNC Mill, CNC laser).

 

[thinmint]

 

[thinmint]

 

[thinmint]

 

[ls7corvete]

Gorgeous build. Resizing the pics would help though. I love the Jig.

Let me know if you want to build another, Ill come buy it from ya. I am in tampa.

 

[soaresdacosta]

I'm jealous... :wink: :wink:
I don't mind to have all those toys, and now how to play with them.
Great build, nice set off components.

Luis.

 

[Brake]

Really cool! Nice job.

 

[Ohbse]

Looks like you've made some great progress!

I am curious, if you ended up going with a cromotor - why sell one to me? Did you end up locating one with the faster wind?

Have you looked at the Adaptto Max-E controller? Will do 12kw, however has large feature set including onboard BMS, onboard charging, onboard configuration of power/presets/throttle/cruise etc etc and generally vastly superior to the Kelly units which have a bad rep for being sluggish off the line in order to protect themselves.

 

[thinmint]

Looks like you've made some great progress!

I am curious, if you ended up going with a cromotor - why sell one to me? Did you end up locating one with the faster wind?

Have you looked at the Adaptto Max-E controller? Will do 12kw, however has large feature set including onboard BMS, onboard charging, onboard configuration of power/presets/throttle/cruise etc etc and generally vastly superior to the Kelly units which have a bad rep for being sluggish off the line in order to protect themselves.

Hey Greg!
I bought two cromotors with the intention of running a dual motors setup, but decided against it for a couple of reasons.
Glad you got the motor, post what you end up doing with it!

Ive looked into adaptto but its price deters me. Not to mention I think the kelly would be the most reliable.

 

[Teh Stork]

Have you done any strenght simulations or calculations regarding this area of the frame? It looks weak. The exact opposite of your swingarm

 

[Emoto]

Ive looked into adaptto but its price deters me. Not to mention I think the kelly would be the most reliable.

thinmint Have you looked at the sabvoton sine-wave, Nice build what does your swingarm weigh 1.5 / 1.8 kg?

 

[carl2.0]

Very impressed by the quality thus far. I'm interested in an Alu frame build sometime aswell,

What grade did you choose, for the tubes what diameter n wall thickness ?

 

[Animalector]

Have you got any comments on the "zoom 680DH" fork? does it appear to be well made / solid construction? I am considering getting one.. (or two)

Thanks
Andy

 

[steam25]

looking awesome!

 

[carl2.0]

I have a Zoom 1100DH Basically the upgrade to that, I got it direct from supplier for around $220 US about a year ago, so far so good. It is no Rockshox so some elements of the build quality leave about to be desired ( like slightly lose dampning adjusters ) the other issue is that replacement parts practically dont exist.

 

[thinmint]

Got some more work done, its unfortunate that all the work goes so slowly but I have nearly no tool access at my university condo. The work basically goes in short weekend long bursts when I have time to travel 2 hours back home and fabricate at a machine shop with actual tools.

 

[thinmint]

 

[thinmint]

 

[thinmint]

 

[Overclocker]

can't wait to see it finished!

what aluminum alloy did you use? and what post-weld heat treatment?

 

[arkmundi]

Beautiful work & congrats! Especially like how you've integrated A123 prismatics into the frame!

 

[thinmint]

Thank you guys

I ride the bike daily to campus, and am still sorting things out. The bike is far from complete, but I did accomplish my goal of completing it before the semester began. I still have lights, fairings, switches, etc to complete.

6061 Alu, hardened.

 

[Animalector]

I just got a fork like yours. does it have any rebound damping control?. mine has very fast rebound and "tops out" ie clunks when fully extended when lifting the front wheel off the ground... Just wondering if mine is DOA or if they are just like this...

Thanks

 

[Scott]

I am using 30S A123 20ah pouches from a past project (Electric S2000)

Good work on the bike Thinmint! I like how you 3d printed the tops of the battery boxes.

Do you have a website or any pictures for the S2000 that you converted to electric? That sounds like a very fun project.

I converted a BMW 330i 2001 to electric in high school. A friend of mine used the same a123 batteries as you did to convert a BMW Z3 to electric.