Deecanios first build the "DC1"

[deecanio]

Hey Y,all,

Yes i have been slack on the bike but i do now have everything i need to build to a rideable state
Jozzer sent my xlyte controller which now has the 4110 mosfet upgrade and an adjustable current pot 8) so i will be able to run with 72v35a as intended for this bike (cheers Joz, i have no idea how he fits all this in his current schedule!! )
I've done some work on the bike myself and if i get a clear run this weekend i just may get a ride
I had a few problems to iron out with the change of frames including new torque arms required, chain slippage, deraileur hassles etc but i have nailed all of these hopefully now and im ready to pretty the batts, give them a charge and go for the first ride on the stinky.
I STILL haven't looked at my batteries and new balancer but im hoping if Joz gets time he can help make sure i know what im doing when charging and i can safely give the batts the deecanio touch
I have taken some pics for you to have a look at what im up to for the usual reasons of getting as many opinions as i can so hollar if you see probs , wathc the order go right out of the window on the pics but i've tried to show clearly what im doing for the torque arms and hopefully they will get the thumbs up??


cheers,


D

 

[knoxie]

Hi DC

Looking nice my man!! cant wait to see some moving video and more pictures!! your bike should rock and roll now!! we must get together and have an e-ride at some point, my Pumas are still running fine, let me know how you go.

Paul

 

[deecanio]

cont..

 

[Jozzer]

Ooooh, lovely work Deec. Nice to see it coming together. Gimmi a call when your ready to charge the batts and i'll talk ya through the balancer connectors.

Ciao!

S

 

[Drunkskunk]

Wow, Nice job on the Torque arms! Any chance you patterened those? I need a set for my Kona Stinky build.

 

[deecanio]

Hey Drunk,

No mate, heehehe if you want some for your stinky just pm me your address and i'll post a drawaround diagram for both sides no problem, you could make a copy with that im sure - i would think you would need the same year an maybe even size so just for info its a 2004 plain stinky 19" frame.


Hey Steve

Yes mate will need your expertise again when you get chance i haven't opened the box yet and its getting a joke now , on the upside i'm sure to 2moro or somepoint at the weekend, believe it or not i have a fookin groin strain at the mo i didnt go in today as weds all i did was take a step, tweak the pull,take another step, etc etc totally anoying and a tad painful too lol
anyways even if i cant pedal i'm still intending to ride
i'll give you a shout 2moro mate

cheers


D

 

[Jozzer]

Ouch @ the strain!

Buzz me anytime after midday....

 

[Ypedal]

Speakin of Buzzz.. he typed that like he had a few pain killers on board lmao....

but on a serious note.. sorry for the painful news.. lol.. i crack myself up sometimes.

 

[deecanio]

hehehe, have had some tonight too
ok so a ride this weekend was a bit optimistic but still a good push in the right direction leaving me odds and ends to sort out but well on its way.
pics up then a few questions before i make the final connections

 

[knoxie]

Hi Mate

Looking really nice! like the balancers! may do something like that with my packs if I have any problems, look nice in the boxes as well, you must get that thing on the road soon mate! I need to do a bit of work on some of my rides as well mate. Will be great to see the bike finished and some nice video and piccies of it all done, we can hook up then, I may knock up something myself, will check with my new lady see if I can get some time off!! ha ha, great to see it taking shape, dont worry about the packs and the tape, 1 of mine I used a tin lid from a presentation box, it fitted great! ha ha, dont go looking inside though it will scare you! ha ha.

Cheers

Knoxie

 

[deecanio]

cont.

 

[deecanio]

Hi Knoxie,

yes i have to get this bike done and im on a charge now - i have to finish the power connections (bit worried about shortening everything down to an inch or so) then im good to go the controller is right next to the power and i have to get the shunt in too - there won't be any room for folded cables everything will get cut to fit!!!!
Apart from the mess of cables everything has been done, i didn't push the cabling tonight as im a bit tired but will get her working during the week or as soon as i find the damn hall connector !!! where did i put that??
Yes ask the mrs for some "me" time then get tuning that 72v bmx - we have business lol
looking forward to some better weather as the forest got a lashing this weekend but soon as the road is dry the bike will be tested
roll on spring mate !!!!!!!!!!!


cheers


D

 

[knoxie]

Hi Mate

Yes looking very good, you wont have any problems with the hall cables mate, the batteries fit the frame really well mate, looks so good! I will get the BMX on the go, it works still but hasnt been run all winter! must get together and have a play soon, the weather looks terrible this week, soon as it clears we must see some pictures and video!!

Knoxie

 

[Jozzer]

Looking good Andy. Great work!
Blade fuses will be fine..

Is it the black rectangular halls connector you need or the din type? (I have loads of the latter if you want me to post 1, and Mark has loads of the black type)

Awfull rain+wind here...theres a UK video backlog....first sunny day youtube will be overwhelmed

 

[fechter]

Yeah, that pesky pile of wires (known in the EV world as "the hairball"). Everyone has the same problem. You start throwing in BMS units, cycle computers, meters, lighting, etc. it can get to be a mess.
Trimming all the wires is a pain, and introduces the chance of miswiring something.

One idea I had is to make a special box to hold all the wires and connections. Make the box out of some kind of plastic and have slots around the opening for wires to pass. When you close the lid, the wires get held into the slots by the lid. Make the slots and the lid on the bottom, so rain drains out and the top acts like an umbrella. The slots make it easier to pull out the wires and connectors for service.

All the wires outside the box can be adjusted for proper length and tidy appearance. Inside the box is another story.

In your setup, such a box might fit under the battery. Perhaps a triangular sort of box.

What are the battery mount frames made from? That looks like a sturdy setup.

 

[deecanio]

Hi Guys,

Cheers Steve, yes its looking very good now, just need to tidy the hairball and we are set!!!
i have put the halls connector (black rectangular) and the phase andersons somewhere safe and now i can't find them!!!
i will have another look tonight and see if i can find them, i remember thinking these will get lost if i dont put them away but i have been over cautious with their safe place
cutting the battery cables is what worries me most - i will only need the batt leads to be 2" or so long given that the shunt goes between i will have to shorten that too.
I will have power to the controller about 4" length so power should be good - all i have of any length is the halls and the phase - these both need to reach the wheel from just above the crank, i have sorted out my route but both are short by 5" or so.

Hi Richard,

yes miswiring is something i am worried about - Steve put a connector on the halls for me and i think he has made the wire change so all i will do is extend it midway down the cable - i think i can do the same with the phase too??
i will need to check all the colours again to make sure everything goes back correctly ( STEVE do you have the colour to colour for xlyte/puma setup? i have it on scraps of paper but not sure where it is, prob with the connectors!!!!).
Thanks for the tip on the slippage Fetchter, the chain isworking beautifully now
The cages are made from angle steel - they are 5mm which in hindsight is a bit thick maybe should have been 3mm? they are rock solid though and i think my batts will be safe in the event of me crashing the bike, which is likely
The box is a cracking idea - i will look into the space i have left, i dont think i will get waterproof connections this time around but it is certainly something i would like eventually.
i dont know why i didn't think of turning the cells this way up in the first place, it makes the cabling easier/shorter and asthetically better.
will get some wiring done this week but as Joz said the weather is awful at the moment, rain and strong winds
Still gives me this week to cable and hopefully will be ready to ride next weekend 8)

Cheers


D

 

[Jozzer]

Hmm, the older motors went
controller blue to motor yellow, controller yellow to motor green, and controller green to motor blue.
Try it at 36v to check its right before zapping it with the full force (may help save the day, a 5A fuse in your holder would be a nice touch too, and of course wheel off the ground. If you cant find a small fuse, steal 1 from your girlies car :lol: ). Like this there is almost no chance at all of anything going wrong
I only mention this since I know you like to be cautious :wink:
Pretty sure that will do it, but, call if you have any grief!

 

[deecanio]

nice one mate,

i'll always test at 36v first, just incase.
Should be ok and i have decided how to cable up - should look really nice with minimal cables all round
will give it a stab this week i reckon so the bike is ready for a ride at the weekend 8)
it's been a long journey - cannot wait to blast the Kona !!!!!!!


cheers Steve,

D

 

[grwsaltspring]

Hi D;

Great photos. (and a very nice looking bike to boot!)

I'm getting lazy as I get older and was wondering if there is a file somewhere on here of "just" your photos starting at the beginning (ie with the pre Kona build) along with the specs on the bike as it has developed. I can't remember all of the mods you have made and just how it was that you came to the Kona

I personally think it has been an interesting evolution that I/we can learn from.

Looking forward to your first ride reports.


Cheers Greg

 

[deecanio]

Hi Greg,

no i dont have the pics alone, i have taken quite a few so i delete them once ive posted them (god forbid this site gets hacked like V !!)
in a nutshell tho mate the stinky has the exact electrical setup i have always had ie - original puma from teamhybrid/xlyte 36/72/35a controller with uprated 4110 fets and adjustable current pot courtesy of Joz, 2 x point one's lipo's from teamhybrid (also uprated by Joz).
I have used the original shortened crack arms i had made early on and have changed the bottom bracket from the spline type to the square type to accomadate them again - i have had custom made battery boxes, custom torque arms and custom DB bracket made too.
The build has taken me forever, some electrical issues and some mechanical hav held me up but it's looking very good now.
The first bike i used was only ever a test bed for the kit and once i knew it was up to the job i bought the stinky as i think it is a fine bike to convert for off road use - i already had the triple crown marzocchi's which i'd bought from ebay so they went on and then i just transferred from all he gubbings from the original bike
i will get the cabling finished this week (tonight i hope) so keep looking here and i will have some video up very shortly!!


Cheers

D

 

[grwsaltspring]

Thanks for the summary D.
Hi D;
That is what I was hoping for.

Any idea what the final weight will be of the bike?

What year is the Stinky and what kind of travel are you expecting out of the suspension?

I don't know if it makes any sense but would it be possible to put a longer rear shock on the bike instead of the shortened cranks? (I realise that you already had the shorter cranks I was just wondering about the geometry)

I've been riding a buddies Turner XCE and picked up a Fisher HiFi Pro for trail riding myself. I kind of talked my buddy into building a new Turner Spot which was done a couple of months ago which has put his Maverick out to pasture along with the XCE so I've been looking at the various bikes wondering about electrification again. Not to mention the Rocky Mountain hardtail that I picked up for road riding which will get the electric trailer project when I get time to make some dimension choices and order the trailer.

Anyway all in good fun!

Very much looking forward to your ride reports, I wonder how it will stack up against the Optibike numbers.

Cheers Greg

 

[Jozzer]

Poor Optibike wouldn't stand a chance IMO

 

[deecanio]

Hi fellas,

hehehe - Joz is throwing down the gauntlet to optibike !!!!! i will be happy if i get the same performance to be honest as opti is lighter than mine by around at least 20lbs but we'll see, i dare say Jamie is a better rider than me too as i have only ridden ten times or so since i was 15!!! man that was a long time ago
Anyway this wekend coming i will be out on the stinky garaunteed, so we will see how my beast lines up against opti!!
i think Richard papa is getting an opti too and Mark is getting some in also so i guess sooner or later at one of the meets this year we will be able to do a straight line race

Hi Greg,

final weight is around 65lbs ish - i will try and get a measured weight for you when i get chance.
the year of my stinky is 2004, 19" frame.
travel on the bike is 7" on the forks and i think 4 or 5" on the tail (im not sure on the rear but it is a fox vanilla shock so i expect at least 4" - it's certainly enough for me!!)
i am hoping to get the same sort of figures as opti - i know at 72v 20a in a 20" wheel my top speed on flat was 32mph - but as Joz has done me a turn with my electrics i can now run the bike at 72v 35a so a good increase in acceleration will hopefully materialise.
Still, all speculation at the moment but i will test it this weekend without fail !!!! (weather permitting!!!)
Check back in a couple of days mate and i will have some figures for you and hopefully some video too


cheers


D

 

[fechter]

Race! Race! Race!
Well, only if you get some video of it.

 

[deecanio]

hehehehe,

i slap optibike twice around the face with my kona glove and challenge it to a duel !!!!!!


D