First E-Bike build - Full suspension, geared & DD motor

[shock]

Got the charger 'monitor' software working. Had to virtualize an XP layer of software since the server box next to my chargers is a linux host.

 

[shock]

Battery documentation

 

[shock]

Having my bike mechanic install a new "fixie" single chain wheel 46t crank. Will locate the chain wheel more center with the freewheel. Also got my second charger and meters today! Now I have cell level monitoring on each bank!

 

[shock]

Permanent parallel.. that's gangster, especially for a first build I hope you did test all the lipos first to rule out any duds.

All the cells tested good for me prior to 'gettin all gansta' with the solider

It is pretty gangster.. but every gang member has his 'tool' handy

 

[docnjoj]

Those are neet charge monitors, like Cell logs but bigger screen. Where'd you get 'em? Also that is a cool stripper cutter. Made in USA? I didn't know we made stuff anymore?
otherDoc

 

[shock]

Doc,

I only buy USA made tools (whenever possible)

I go the monitors from hobbypartz.com

 

[docnjoj]

I wish I could only buy USA made but I am a sucker for HF stuff when it is of good quality. Most of my power tools are DeWalt, however like the chop saw, reciprocating saw and drills.
otherDoc

 

[shock]

Got my bike back from the mechanic today. Woo hoo! Got some new bling installed, main chainring now 46t, with more of a road style crank. Also picked up some new thermalite pedals to add a splash of color.

 

[biohazardman]

Good to see the road crank you have a pretty big choice in the taller gears with that installed. I run a 53 up there and 11 in the back so I can pedal usefully at 30MPH+, leasurely at 20-25.

 

[BATFINK]

Hello guys, I hope you don't mind me asking biohazard about his setup. You have 53t up front and 11t on back. What is standard for the average mountain bike. I feel like I'm getting no pedal power to my wheels above 25mph and this sounds like exactly what I need to do. How do I go about changing it? Is that the maximum combination you can get?

Sent using Endless-Sphere Mobile app

 

[BATFINK]

Also to Shock, I notice you only have one chainring on the front. That would be great as I could do away with a gear lever and another cable. How do you find pedaling it if you ran out of battery. Is it manageable?

Sent using Endless-Sphere Mobile app

 

[shock]

@biohaz, I would like to go bigger but I think 46T is max on this full suspension frame (check out the clearance on the lower rear arms ) Either way I'm slowly getting taller gearing (a 44T was removed)

@BATFINK, I think most mtn bikes use a 44T high gear (in my experience so far). My main reasoning to go with a singe chain ring was to get rid of the front shifting system, cables, extra sprockets, etc. I'm always in the high gear anyway on the front, so less weight, less complexity, and more battery space . For me it's no problem pedaling as my rear freewheel has a super low range 34T chain wheel if I need to climb a hill. One limiting factor for me right now is that my freewheel only goes down to 13T. More reliable than the 11T, but those two teeth make a lot more difference for a high gear. So right now my high gear is 46T front and 13T rear, which I can pedal pretty comfortably at 25mph. Past 25mph that 11T would really shine

 

[shock]

Took the bike for a ride tonight, another good 6 miles. No issues at all with the new crank setup, and I have not even charged the batt after the last run and im still at 3.8v per cell

Man I really need a 11T gear on the back

Testing conditions 34* - Artic ebike

I'm really happy with the range this thing gets so far with 8 amp hours on board. 12 miles easily so far without much batt voltage sag.

Also got 2 flashlights mounted up with some cheap ebay mounts-- really need to fond some decent clamp style flashlight mounts....

Heres a blurry frozen phone picture of the bike proped on a picknic table, and the current dashboard

 

[kfong]

Looking good, I see you rode to Metro beach. Crazy weather we have been getting. I was hoping to kiteboard there this past weekend but got rained out. Now I'm hoping for good ice so I can get my ice board out. Have not ridden my mountain bike since fall. It's all apart for upgrades. Bummed, since there have been a half a dozen warm days to ride. Just won a fox rp23 rear shock. Bike is going to be rockin this summer with the new batts and shock. Just got my delivery of carbon fiber for the new covers. Only thing left to address is the rear brake. It was damaged last fall, but works. Not sure if it's reliable. Still haven't started on my DH frame. All these bike builds have been taking up a lot of my time. Still hoping to get them all running by spring. Working on the motor mounts for my RC build, should have a major part of it milled out by today.

What's the final battery setup you were planning on. Those packs we bought all tested good. I will have a kw on the bike, allowing me to ride to my trails without my car.

 

[shock]

You called it kfong! So far I've been using 6 packs in a 12c3p configuration. I have 4 more packs, but wanted to start simple and work my way up.

I am split looming the controller wires to clean the up and protect them.

Also got the dual head charger up and running.

Lastly I added to the solar recharging station , an unexpected twist!!

 

[kfong]

Not much sun these days. I wonder how effective it will be. I hear the solar panels on eBay are getting cheap. Tempted to get some myself to play with but not sure it would pay for itself.

 

[shock]

Not sure how much current this panel puts out, but i measured voltage today with my meter and it was showing 15v in the light. I got the panel for free from my uncle-- he made it, and got the batt for free from a friend, so I figured I would at least trickle charge the batt. Time will tell how effective the solar setup is,

 

[shock]

Went for another ride, 7 miles fresh off the charger. Dry and calm but 30*. Man I can't wait for 70s !Aired up at the gas station, took a pick of the bike in action. Been wearing my full face motorcycle helmet, its warm and I feel safe in situations I get myself into with traffic. Also did a little off roaring this time and muddied up my tires and lower tube.

 

[shock]

After the last ride I did a thorough inspection of the frame and mounting hardware. The pivot point of the rear suspension had worked itself loose by a few turns. Originally when I received the frame I sprayed some WD40 in there to make sure water gets displaced, but I may have over did it a bit as when I took it apart, it was completely saturated with oil! So I cleaned off the excess oil, dried the threads and reassembled with some blue loc-tite. Has been fine ever since. So yeah there is 3" of snow on the ground right now, but tomorrow is supposed to be high of about 50* so may have to recharge and take advantage of that. I'm really glad I was able to get the bike running much quicker than expected and start riding. I'm still working on the case, but may go a different route. The velcro strap system seems to be working great, and I like being able to remove the battery for charging and storage, as I can put it in a steel box and not worry if it decides to catch fire or something

 

[vintagerider]

wow very cool bike, i am just contemplating building my first e-bike and i also live in se michigan, we might even be able to ride after i get mine built.

 

[shock]

I'm down to ride all the time

Good luck with your build, If you have any questions let me know.

Charging right now. It seems my dual AC6 setup charges at 2.3 amps max. Even if I set it to 5 amps, the computer in the AC6 limits the current to 2.3. I assume this is due to the batteries only accepting this much current safely. They are 20c.

 

[kfong]

Hey another local ebiker. Have to do a group ride this summer.

 

[shock]

Batts charged to 24.2 volts each bank and quit with a 2 hour limit

These LiPo's are hungry, going to charge to 25v each and take em out on a ride. Can't pass up a 55* Michigan January day.

 

[shock]

nearing 25v per bank...

going to attempt a 20 mile round trip.

Chargers in backpack to top off at 10 miles

 

[shock]

20 mile journey was a success Ran along the coast of lake st clair from harrison twp., to SCS 9 mile and mack.

Was able to use my brothers garage to recharge while we ate dinner. I actually think I could have went 20 miles, or at least been pretty close, as after 10 miles the pack was about halfway discharged. Overall the bike performed well, I'm really liking this motobecane trail frame, I hit sidewalk drops and ramps at 20mph and don't even feel it! What i didn't judge is how much water would still be present on the sidewalks, so my outfit and bike got pretty wet and muddy! I need to find some tire flares / shrouds so I don;t get sprayed so much!