Custom Battery Cyclone 3000 Downhill Bike

[KaiKall]

This has been in the works for quite a while now. I still have a bunch to do but the bike is finally in working order.

This is the first big ride i have done so far, went 65km using just over 1100Wh, the bike is much easier to pedal than i expected.


Specs:
2008 Kona Stinky Downhill Bike Frame
Cyclone 3000w mid-drive
Kelly KBS72121X controller on custom aluminum heatsink
Custom 72V 21ah pack made from ncr18650ga cells
80A BMS
12V DC-DC converter for lights and acc.
Cycle Satiator for charging
Maxxis Holy Roller tires (these are great so far)

The battery box is made of polycarbonate sheets solvent welded together. The side panels are held on with the through bolts. I originally made the box with epoxy, but a few of the panels become loose just in test fitting. Had to tear apart and redo the whole box.

Batteries are held by 3D printed spacers. I was originally going to do a compression connections for the battery, similar to this: https://endless-sphere.com/forums/viewtopic.php?t=57810 but due to the bolt spacing I couldn't get even pressure and not all the cells made connection.

After a few goes i scrapped the idea on this bike and had the pack spot welded instead. I may try on a future battery with a more regular shape.


Made custom mounting for the cyclone to increase the ground clearance and to minimize the flexing with the stock bracket. 3D printed Chain guard.
View attachment 20220502_171229.jpg
The panel on the other side of the bike I am still figuring out what to do design wise, maybe something with back lighting, but for now it just has a sheet of vinyl on the inside.

Had to cover up the wire mess to ride in the city, don't want the bomb squad called!

This is now my primary transportation and now has its own parking spot in my apartment.
View attachment 20220508_162832.jpg

Things still to do on the bike:
Make a custom rack and fenders
Bash guard for the motor, kickstand both to attach to the motor mounting brackets.
Side panel design/lighting
Ordered a new crank freewheel as the stock seems loose after only 200km.
Motorcycle Dashcam? -not sure if its needed.

This site is responsible for all the work that went into this project and I could not have done it without all the knowledge here. I want to do the same so any questions about the bike I will try to answer.

 

[Stealth_Chopper]

Nice work, K, your's is one crafty disguised hard wired creation.
What's the gross weight bike & pilot? Which rear shock?
Composite fenders?

 

[KaiKall]

Thanks,

Bike is 80lb and i am about 200. The rear shock is a roco, came with the bike when i bought it. I had to dial the pre-load up quite a bit as the suspension is super soft when setup for downhill.

I want to make some fenders out of sheet metal and weld it to a custom rack as one piece, going to start with a cardboard mock-up and go from there. If i cant get my welding buddy to help i may go fibreglass.

 

[problemaddict]

Impressive build!

 

[sviatpizdat]

Amazing bike! What about max speed? Can the bikecycle transmission handle the high engine power ?

 

[KaiKall]

Update to the Build after 2 years and approx 7000km.

The original cyclone motor burned out after about 4000km. I was never too happy with the ride feeling of the throttle and the bike did not reach the expected top speed. Torque on that motor was insane however, ended up breaking 3 chains over the 4000km.

After the cyclone went I switched to the cyc x1 pro gen3. At the time I also switch the derailleur and got a larger rear gear for better torque. (The CYC has much less low end torque than the cyclone did) I love the feeling of this setup and now ride the bike quite often with pedal assist. The bike now tops out over 80km/h and with the low gears still has amazing hill climb ability.

 

[pwd]

I'm a little surprised the Cyclone has burnt out and only lasted 4000km. I suspect your crank to cassette gear ratio may have been not been enough and the motor rpm's may have been too low. The comparison between the CYC and the Cyclone is nice to see/good info. How loud is the CYC compared to when you were running the Cyclone?