First E-Bike Build Scott Aspect

[JoeFR]

Hello guys

After long time waiting on all the parts, designing a battery box, waiting for machining workshop to finish my parts, here is the finally finished conversion from Scott Aspect bicycle to E-bike.

Here are some data:
Frame: Scott Aspect 35
Motor: Crystalyte X5305 on 26"
Contoller: Lyen 18 x 4115 MOSFET 84-132V
Battery Pack: Li-Po 100V 20Ah ( 16 x Turnigy 6S 5Ah 20C 24S 4P )

Because pictures tell more than 1000 words, here is the build log with pictures:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/0_Scott_Aspect35.jpg

All parts

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/1_Komponente.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/2_Komponente_1.jpg

Li-Po Battery frame fitting testing:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/7_Li-Po_Turnigy_6S_20C_5Ah_BatteryBox_1.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/8_Li-Po_Turnigy_6S_20C_5Ah_BatteryBox_2.jpg

SketchUP Battery box design:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/81_Alu_BatteryBox_Design_SketchUP.jpg

Testing Battery box fitting in the frame:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/9_Alu_BatteryBox.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/91_Alu_BatteryBox.jpg

Balance DB37 connector:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/6_Li-Po_Balance_Connector_DB37_4.jpg

Making Battery box carbon fiber look:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/93_Alu_BatteryBox_CarbonFiber.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/95_Alu_BatteryBox_CarbonFiber.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/96_Alu_BatteryBox_CarbonFiber.jpg

Test fit battery box to frame:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/98_Alu_BatteryBox_CarbonFiber.jpg

Fitting Li-Po, cables, connectors to battery box:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/992_Alu_BatteryBox_BatteryInstalled.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/993_Alu_BatteryBox_BatteryInstalled.jpg

Bonding the velcro straps to Li-Po pack:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/994_Alu_BatteryBox_Velcro.jpg

Fitting the middle aluminium wall to battery box:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/995_Alu_BatteryBox_SrednjiPokrob.jpg

Finished battery box:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/996_Alu_BatteryBox_Complete.jpg

Programing controller:

Finished E-Bike:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/997_E-Bike_Complete_1.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/998_E-Bike_Complete_2.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/999_E-Bike_Complete_3.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/999_E-Bike_Complete_4.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/999_E-Bike_Complete_5.jpg

 

[torker]

All I can say is "wow" Welcome to the forum.

 

[johnrobholmes]

Yeah, really!


Have you weighed it yet?

 

[boostjuice]

Great work on that battery enclosure! It's amazing how easy it is to fit 2kwh worth of lipo into the frame these days. Nice job with the DB37 balance lead connections as well! Top work!

 

[AussieJester]

Outstanding work hell of a first post! Welcome to the forum... Obviously you
have been doing ALOT of reading here & understood it completely then went forth & built a
very very nice ebike! Loving the alumnium battery enclosure covered in the 3M film and the use of
a DB37 connector is fantastic i see GGoodrum lvc boards in the mix, smart move IMO ... 100v 20ah
of lipo goodness, i see 3 meanwel there too, charging times must be outstanding!

Bit of a Kick in the face to those here that say lipos shouldn't be recommended to noobies...
:-S Thats hands down one of the cleaniest lipo setups on Endless Sphere!

Awesome work mate...Pity theres snow on the ground, would love to see the bike in action!

KiM

 

[torker]

+1 on the 3M carbon fibre look alike. Also high marks because AJ actually complimented a hub setup jk

 

[AussieJester]

+1 on the 3M carbon fibre look alike. Also high marks because AJ actually complimented a hub setup jk

Contrary to popular opinion, i have complimented many bikes on this forum that use hub motors. If a member puts
the time and effort into their rides its worthy of compliments regardless of what makes it move ..IMO :wink:

KiM

 

[beast775]

excellent ebike! top of the line.that enclosure is wicked ..

 

[mud2005]

nice build! I like the 3M carbon fiber look, very nice

 

[GTR2EBIKE]

That is certainly a hell of a first post. You did an awesome job on that battery enclosure, it doesn't hurt to have 2000 WH in their either.

 

[John in CR]

That's a hellofa job on a first ebike build! How's she run? You're going to have a really long winter waiting for spring and good riding weather.

 

[docnjoj]

Wow! How did you get the bend lines so clean? Sheet metal brake? Welcome and double wow!
otherDoc

 

[gogo]

Super Slick! I especially like the Velcro battery mounting.

 

[JoeFR]

Thanks guys for all the nice words off my first build
I have to thank the ES forum members where I find all the info I needed to complete this build

So lets make some answers to the questions you have posted:
johnrobholmes Have you weighed it yet?
The weight of the e-bike is about 43kg or 95lbs

AussieJester John in CR
We have now winter conditions in our country on full scale. I have to wait until spring and then make some videos.
I have tested the e-bike 1 week before snow start to fall, and the e-bike performs very well.
Very good acceleration and top speed over 70km/h. And the range is very good too.

docnjoj How did you get the bend lines so clean?
The aluminium box was laser cut from 2mm aluminium sheet. The edges were bended on bending machine.
Then the free space between the edges was welded together.
The machining shop did a very good job, because the size of the box is perfect fit to design in SketchUP.

 

[beast775]

is there any pics of the plug in-outs on the box while on the bike? im wondering how you did that so neat and hidden? very good work.

 

[JoeFR]

Hello beast775 here are the pictures:

Balance Connector DB37:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/9991_BalanceDB37Connector.jpg

Charging Anderson connectors
I could charge and balance each of the 6S4P li-po pack separately or make a 24S4P bulk charge:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/9992_AndersonChargingConnector.jpg

Fuse holder:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/9993_FuseHolder.jpg

Aluminium cover for connector and cables, which Is attached to the battery box with velcro straps:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/9994_CoverforCablesandConnectors.jpg

 

[JoeFR]

Today I record first video with my contour gps camera:
[youtube]B4fkkd0EjN0[/youtube]


and here are some CA data:

View attachment 4


View attachment 1

 

[beast775]

thanks for filming that .awesome video.excellent roads and buildings.reminds me of my terrain outside of the city centre here.thanks for posting the c a numbers.

 

[Bazaki]

Great bike, great pictures.
I see 2 torque arms, did you install them both ?

 

[JoeFR]

Yes Bazaki I install both torque arms so that I dont have problems with axle twisting

BTW I record two new videos:
Climb
[youtube]uiFvOzyCnjk[/youtube]

Downhill
[youtube]p4TF4QtK0mw[/youtube]

 

[Bazaki]

Nice videos.

Did you install both torque arms to one side, maybe you can take a picture ?
What values did you fill in the phase and rated current in the controller software.

Thanks !

 

[GCinDC]

Sweet!

I haven't figured out the radial display. What's it measuring?

How are the bumps? Have you considered at least a seatpost suspension..

 

[boostjuice]

Sweet!
I haven't figured out the radial display. What's it measuring?

Accelerometer/G-sensor. It's one schweeeeet camera, but boy does it cost! $400~$500

 

[JoeFR]

Hello Bazaki

Here are the controller setings:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/Lyen_18Fet_Settings.jpg

Here are the picture of torque arms installed:
Left side:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/Torque_Arm_Left.jpg

Right side:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/Torque_Arm_Right.jpg

Hello GCinDC
How are the bumps? Have you considered at least a seatpost suspension..

I try to avoid bumps as much as possible. And yes I am thinking to change to seat with suspension

 

[Bazaki]

Thanks for the pictures !

About the LVC at 40,5, isn't that way too low or don't you use it ?
Do you really use 50 amps from the battery to the controller ? Did you measure this with the CA to check if it is true ?

I set my 18 fet Lyen controller to 57 amp and I only draw 30 amps. I would like more amps, like 75, but the menu doesn't get higher then 57 amp