Danny Mayes
1 kW
Tidy work AJ.
My fingers are crossed for you bro
D
My fingers are crossed for you bro
D
Custom_CHRoMo_CRuiSER
- Thread starter AussieJester
- Start date
jonescg
100 MW
Ready to rock and roll
AussieJester
1 TW
BooYaaaH CHRiS!! Well done mate shall cya ya on the wekend for some battery building and drinking funz LoL...
@ Danny, Cheers mate, was alot more time consuming doing the freakin termination wring than i thought
i am a fuss frocker when it comes to neatness so that slowed things down... i just hope the bloody thing
works as my back up plan is re-wiring the Turnigy 80-100 LMAO...in bed with bad
leg spams as i type this hoping yhis afternoon i can get to the motor dosed on "medication"
tp deal with the pain still, anxious to see if this works ...
KiM
@ Danny, Cheers mate, was alot more time consuming doing the freakin termination wring than i thought
i am a fuss frocker when it comes to neatness so that slowed things down... i just hope the bloody thing
works as my back up plan is re-wiring the Turnigy 80-100 LMAO...in bed with bad
leg spams as i type this hoping yhis afternoon i can get to the motor dosed on "medication"
tp deal with the pain still, anxious to see if this works ...
KiM
AussieJester
1 TW
Been wanting to post results all day but Internet has been down, long story short
it spins!
[youtube]C5skbWKeJJY[/youtube]
I didn't have a Cycle Analyst or Battery Medic handy i did howver download
the Castle creations data log--->
Few assorted pics of assembly and size comparison to the motor its 'replacing'
i.e Turnigy 80-100 130kv V1
Replacement shaft Thud sent my way, i drilled a 'divot' in it for the set screw.
Finally together and working but why all the effort?
I dug up an old brushless 36v controller Hyena sent with a frock motor i had for a drift trike
i shall attempt to get hall sensors mounted at 120 degrees on
the CA120 and connect it to the ebike controller, see if i can have a win getting a sensored
motor running.. i did smile when the RC ESC played its syncing tune hehe..
More tomorrow with a lil luck
KiM
it spins!
[youtube]C5skbWKeJJY[/youtube]
I didn't have a Cycle Analyst or Battery Medic handy i did howver download
the Castle creations data log--->
Few assorted pics of assembly and size comparison to the motor its 'replacing'
i.e Turnigy 80-100 130kv V1
Replacement shaft Thud sent my way, i drilled a 'divot' in it for the set screw.
Finally together and working but why all the effort?
I dug up an old brushless 36v controller Hyena sent with a frock motor i had for a drift trike
i shall attempt to get hall sensors mounted at 120 degrees on
the CA120 and connect it to the ebike controller, see if i can have a win getting a sensored
motor running.. i did smile when the RC ESC played its syncing tune hehe..
More tomorrow with a lil luck
KiM
jonescg
100 MW
Good stuff mate. I just spent the last few hours putting my 5800 mAh pack together. If anyone asks why I'm using the 40C cells and not the lower ones - two letters. Q C. Man HK really drops the ball on these lower C rate cells - 3 duds in 37 cells!
I have ordered more to finish the 20s3p pack. Why am I telling you this? Cause I got a sweet way of finishing the pack and keeping the balance leads neat. Will post pics up soon
I have ordered more to finish the 20s3p pack. Why am I telling you this? Cause I got a sweet way of finishing the pack and keeping the balance leads neat. Will post pics up soon
Danny Mayes
1 kW
Woot! Good work bro! Delighted to see it spinning happily.
I bet it filled you with joy and was quite the relief when it span up. Fitting halls sure beats another rewind.
It sure looks cool, those windings through the can.
Your last contraption hauled ass, this one will be off the hook...
D
I bet it filled you with joy and was quite the relief when it span up. Fitting halls sure beats another rewind.
It sure looks cool, those windings through the can.
Your last contraption hauled ass, this one will be off the hook...
D
gwhy!1
100 kW
Hi KiM, just thought I would give you the heads up about you trying a e-bike controller for sensored control, nearly all non-infineon e-bike controllers that I have played with will have problems above speeds of around 4krpm (this is on the smaller motors with lower pole counts ) so just be a bit carefull when you start to ramp the speed up as it may get to a certain speed then start drawing massive amounts of current.
Byte
1 kW
That motor is huge and looks awesome! Good luck with it 
Farfle
100 kW
Big MoFo outrunners are awesome man! That thing looks sick!!
jonescg
100 MW
I'll come over on Sunday KiM!
If you want to start tinning the copper you are most welcome. I F'n hate that job. But if you like I can bring some pre-tinned copper over. I'll bring a bit of G10-FR4 and some 18 G wire too. Keep them beerz chilled OK? Coopers pale thanks
If you want to start tinning the copper you are most welcome. I F'n hate that job. But if you like I can bring some pre-tinned copper over. I'll bring a bit of G10-FR4 and some 18 G wire too. Keep them beerz chilled OK? Coopers pale thanks
AussieJester
1 TW
jonescg said:I'll come over on Sunday KiM!
If you want to start tinning the copper you are most welcome. I F'n hate that job. But if you like I can bring some pre-tinned copper over. I'll bring a bit of G10-FR4 and some 18 G wire too. Keep them beerz chilled OK? Coopers pale thanks
Wicked!! Coopers Pale ale for CHRiS weed and Bourbon for KiM...
@GWHy cheers for the heads up, i just want to get her running, if i get her turning with halls
ill be convinced enough to drop large money (for me anywayz) on a decent Kelly to run her full power
@Farfle Agreed! love the big MOFO Outrunners, yours is king of them all LoL :wink:
Cya Sundee CHRiS
KiM
AussieJester
1 TW
Firstly apologies to jonescg for taking so damn long getting the
balance wires and connection done so i could post the finished 'product'
I speak of course of the custom 72volt 15ah Lithium Polymer pack using
the lipo boards jonescg has available!
I decided on DB25 connections for the balance wire 'termination' if you like, i will
be charging the pack with dual 36v meanwels soon as i have the $$$ for them in the intrim
i will use the Hyperion to charge/balance via the balance taps sooooo...
jonescg Provided
material to cover the buss bars, i cut these and notched the pieces arranging the wiring.
With the wires arranged I quickly called 1000w (Matt.P) to get a freakin clue how i was meant
to wire the balance taps to work on the Hyperion with its two X 7s ports (A)&(B) As usual Matt
knew what the go was, we promptly numbered the wires accordingly ran through it a second time
and then.................. a month later i still hadn't done a freakin' thing and needed a reminder
so on the phone again and god bless him out came Matt again Thursday night on his
e-bike! Went through the show again, next day was when i got into it...
Theeeen... with the wiring complete i plugged it into the Hyperion and crossed fingers LoL
The cells have been here for months now and have remained on ~3.85v I was
starting to stress a little thinking they would need a top up, seems though they are
good to go, i will cycle them slowly and grab me a pair of meanwels to bulk
charge via the main leads ASAP...
I have picked up some 8 and 6mm alumnium to begin the suspension seat
setup, hope to have some updates later today early tomorrow on the progress of that...
Anyone interested in a custom liPO pack like above contace CHRiS jonescg and
he can sort you out
ciao for now
KiM
balance wires and connection done so i could post the finished 'product'
I speak of course of the custom 72volt 15ah Lithium Polymer pack using
the lipo boards jonescg has available!
I decided on DB25 connections for the balance wire 'termination' if you like, i will
be charging the pack with dual 36v meanwels soon as i have the $$$ for them in the intrim
i will use the Hyperion to charge/balance via the balance taps sooooo...
jonescg Provided
material to cover the buss bars, i cut these and notched the pieces arranging the wiring.
With the wires arranged I quickly called 1000w (Matt.P) to get a freakin clue how i was meant
to wire the balance taps to work on the Hyperion with its two X 7s ports (A)&(B) As usual Matt
knew what the go was, we promptly numbered the wires accordingly ran through it a second time
and then.................. a month later i still hadn't done a freakin' thing and needed a reminder
so on the phone again and god bless him out came Matt again Thursday night on his
e-bike! Went through the show again, next day was when i got into it...
Theeeen... with the wiring complete i plugged it into the Hyperion and crossed fingers LoL
The cells have been here for months now and have remained on ~3.85v I was
starting to stress a little thinking they would need a top up, seems though they are
good to go, i will cycle them slowly and grab me a pair of meanwels to bulk
charge via the main leads ASAP...
I have picked up some 8 and 6mm alumnium to begin the suspension seat
setup, hope to have some updates later today early tomorrow on the progress of that...
Anyone interested in a custom liPO pack like above contace CHRiS jonescg and
he can sort you out
ciao for now
KiM
jonescg
100 MW
Very neat KiM!
I was around at Matt's place last night finishing the polycarbonate box for my 74 V, 17 Ah LiPo pack. I'll finish it up today and post some pics.
Oh, I have a pressie for you, so I should pop around some day soon
I was around at Matt's place last night finishing the polycarbonate box for my 74 V, 17 Ah LiPo pack. I'll finish it up today and post some pics.
Oh, I have a pressie for you, so I should pop around some day soon
Danny Mayes
1 kW
Wow! Looks amazing Kim. Neat job as always.
D
D
AussieJester
1 TW
jonescg said:Very neat KiM!
I was around at Matt's place last night finishing the polycarbonate box for my 74 V, 17 Ah LiPo pack. I'll finish it up today and post some pics.
Oh, I have a pressie for you, so I should pop around some day soon
Yes very happy with the pack, it so freakin' tiny hehe...A "pressie" hrmz...your out of work i dont work
you know where i live..i'm home all weekend/week LOL... Give me a hint Santa CHRiS
@D-MaN...cheers matey, you been very quiet of late! Have to have you and Karen around for Bar-b-q
again soon, weathers heating up, we got the pool ready for summer! shall give you a buzz soon bud.
Back to cutting aluminium joy joy LoL...keep forgetting how much bloody time this sh*t takes
god damn, "just knock this bracket up" takes freaking hours/days LoL
...things is GO GO GO with fabrication again! OH i also received yesterday
two tins of electric motor winding 'varnish' for the rewound Turnigy CA120 will also
coat the 80-100 Turnigy i have here on the two speed
Thud rewound, likely be fitted to the bike initially to get her running...
....back soon chaps
KiM
Hyena
10 GW
About time you posted an update ya slacker!
Good to see things progressing. I take it you've been too busy with your feet up to work on ebikes ?
Good to see things progressing. I take it you've been too busy with your feet up to work on ebikes ?
jonescg
100 MW
AussieJester said:... Give me a hint Santa CHRiS
Well it's about 6 inches long, has a thick blunt end and is hot hot hot
Danny Mayes
1 kW
Hyena will have a field day with this one :lol:
AussieJester
1 TW
jonescg said:AussieJester said:... Give me a hint Santa CHRiS
Well it's about 6 inches long, has a thick blunt end and is hot hot hot
LoL@Danny.... uhm...no Jay, CHRiS aint describing your under equiped "manhood" i believe though, he maybe
describing a soldering iron? gimmee gimmee gimmee gimmee LoL..cheers CHRiS
I have nearly finished the seat/suspension setup, all ali is cut and sanded etc, i need to do some
drilling and tapping tomorrow to get it all in one piece, I also spoke to Mr Matt.P
this afternoon and asked if he could do a small TiG welding job on the mount for me, he agreed
cheers Matt
I will post pics tomorrow when all the bits are assembled...
Time for a beer!
KiM
Spicerack
10 kW
Did someone say beer? I'm going to have to come round and inspect this rig before too long mate! Been busy- you know how it is when you're unemployed!
AussieJester
1 TW
Head on over anytime you like Andy, you have my new addy in high Wycombe?
KiM
KiM
Spicerack
10 kW
Nope, and lost your mobile number too when my ifail carked it.... pm me if you wish...and I'll fix the flat on my bike and whizz over next week?
AussieJester
1 TW
No worries Andy will catch you up end of the week
Well, i made alot of progress Friday but didnt get around to posting pics till now!
I began work on the suspended seat mounting setup, no idea how well
it will actually work, but i think it will look neat LoL..
We started off with making a cardboard template from which
a new mounting plate for the seat was fabbed, using 6mm ali -->
Using angle grinder and cut off disk to cut the 6mm plate
View attachment 14
The plate needed to be 'bent' in order to match the profile of the seat
pan, i cut along the bend line and proceeded to bend to shape, Matt.P
will run a TiG weld along the bend line for me, cheers Matt...
With the mounting plate cut, i moved on to the side plates
that will be bolted/tigged to the mounting plate-->
View attachment 13
We are using 10mm alloy for this HOWEVER initially i cut these plates
from 8mm before realising i had enough 10mm thick ali
to do the job, the original 'seat pivot' was made from 10mm-->
The two plates were bolted together and 'matched' up on the Linisher
The mounting holes were marked, centre punched drilled and tapped
to take 6mm bolts...
View attachment 9
As with the bend in the mounting plate being Tigged by Matt, these side plates
will also receive some TiG treatment for a little 'added' security i.e keeping my ass
off the rear wheel if it broke LoL...
Top tube of the frame was drilled and the seat mounting affair 'mocked up'
View attachment 3
Obviously alot still to do, a 10mm bolt will be used along with sealed bearings on the pivot
the bearings still require fitting, i also will weld a 10mm tube through the pivot hole
to ensure the top tube isnt worn/crushed...Mounting of the FOX shock must also
be done, i do have a lighter weight spring to fit to the shock also.. :wink:
OH, and yes ALOT more shaping of the ali to be done including "lightning holes"
I also cut the slots in the rear dropouts, couldnt resist popping the box/motor on
for a squizz-->
Starting to look more like an e-bike! LoL Weather is heating up so will didvide
time between swimming and fabricating teehehe... Hows the snow in North
america YPedal MaN teehehehe
Back with more Soon
KiM
Well, i made alot of progress Friday but didnt get around to posting pics till now!
I began work on the suspended seat mounting setup, no idea how well
it will actually work, but i think it will look neat LoL..
We started off with making a cardboard template from which
a new mounting plate for the seat was fabbed, using 6mm ali -->
Using angle grinder and cut off disk to cut the 6mm plate
View attachment 14
The plate needed to be 'bent' in order to match the profile of the seat
pan, i cut along the bend line and proceeded to bend to shape, Matt.P
will run a TiG weld along the bend line for me, cheers Matt...
With the mounting plate cut, i moved on to the side plates
that will be bolted/tigged to the mounting plate-->
View attachment 13
We are using 10mm alloy for this HOWEVER initially i cut these plates
from 8mm before realising i had enough 10mm thick ali
to do the job, the original 'seat pivot' was made from 10mm-->
The two plates were bolted together and 'matched' up on the Linisher
The mounting holes were marked, centre punched drilled and tapped
to take 6mm bolts...
View attachment 9
As with the bend in the mounting plate being Tigged by Matt, these side plates
will also receive some TiG treatment for a little 'added' security i.e keeping my ass
off the rear wheel if it broke LoL...
Top tube of the frame was drilled and the seat mounting affair 'mocked up'
View attachment 3
Obviously alot still to do, a 10mm bolt will be used along with sealed bearings on the pivot
the bearings still require fitting, i also will weld a 10mm tube through the pivot hole
to ensure the top tube isnt worn/crushed...Mounting of the FOX shock must also
be done, i do have a lighter weight spring to fit to the shock also.. :wink:
OH, and yes ALOT more shaping of the ali to be done including "lightning holes"
I also cut the slots in the rear dropouts, couldnt resist popping the box/motor on
for a squizz-->
Starting to look more like an e-bike! LoL Weather is heating up so will didvide
time between swimming and fabricating teehehe... Hows the snow in North
america YPedal MaN teehehehe
Back with more Soon
KiM
Ypedal
100 TW
I had the snowblower out today... nuff said
liveforphysics
100 TW
If you want it strong mate, dont have him TIG the bend, each weld reduces the temper of the alloy in the HAZ dropping it to T-0 or T-1, and I bet its likely at T5 or T6 right now.
Great to hear from you buddy!
Great to hear from you buddy!
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