Ebike update

brainfarth

100 mW
Joined
Feb 16, 2013
Messages
45
Location
Oregon City, Oregon
It's been a while since I have shared anything about my bike build...
It's around 2 years old now since I first purchased a Papa Motors 48v 15ah kit for around $1200. Since then, the Ping battery died because of faulty BMS(s). So I purchased a bioenno power batter (48v 20ah). The BMS that came with it was garbage, so I bought a new one from dnmun.
I built the box and rear rack out of 3/8" aluminum round and .090 plate. I had to double hinge it because of the lip around the lid to keep things dry. And I modified the rear latch so it doubles as a lid lock and holds the box to the rack frame. It's also over sized to I keep some tools back there. I also squeezed two DC/DC buck converters rated at 60v in and one set to 5v out and one to 12v. I picked up some water proof switches, 3 pin aviation plugs and a thru-wall USB plug for connectivity. The 5v charges my phone or powers the cheap walmart front blinky light. The 12v is for the heated hand grips that I broke (didnt have enough glue on the right one and it pulled off along with the wiring).
Also, I machined some plates that the rear axle nuts slip into so that they can never come loose enough to fall. Also, the bolt that holds the mounts that the rear rack sits in doubles as the torque bar. They rest in the frame corner to keep things from spinning out of control.
I also have an ion 700 which is a great light for the price and a sony action cam on the front.
The front fender is easily removable. There is a clip on the top that slips over the forks and the side bars slip into holes that I drilled into some stainless pipe clamps.
And I have plenty of videos on my http://www.youtube.com/brainfarth account with my rides.
Oh... The first pic is of the box not closed all the way.
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@snow-fork - whoa. What's the bottom part made of?
Build looks pretty fun, but I think a lot of people will look at the balance of your bike and get worried. Have you considered any triangle bags or options to put that battery weight in the triangle? You gots so much space in there.. thanks for sharing!

What happened with the Ping battery BMS, do you know?
 
It was just a piece of plywood. Next time I will use kids ski's.

And I measured the space within my frame, drew it up in autocad and tried to squeeze the pack inside. No matter how I broke it down, I could not make the cells fit without them hanging out of the sides too far. I thought about splitting it up between the middle and place the leftover cells on the back, but that was more work that I wanted to do.
 
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