First E-Bike Build Scott Aspect

[beast775]

that is quite the climb! looks like ebike heaven there.

 

[mud2005]

I like the looks of those torque arms can I ask where you got those

 

[Bazaki]

I just found a second controller software program, Lyen program
Now I can put the field up to 100A, I just drove with 75 A and that is really sick, extremely fast !!

 

[GCinDC]

I like the looks of those torque arms can I ask where you got those

Musta got them from Amazon.com, huh? Sheer coincidence, blind luck they match the exact shape of the right and left dropouts, right..? :lol:

Stainless, I presume? Wet cut? Are those lock nuts too? Or is that loctite?

This is a crazy first build. I almost don't believe it...

 

[JoeFR]

Hello Bazaki

I got this formula from Lyen for LVC: 79.2v = (64+2)/2 = 40.6v
I have set the controller to 50A battery current.
At WOT after 5 seconds my CA shows between 45 -50A

Hello mud2005 and GCinDC
Stainless, I presume? Yes Wet cut? No laser cut Are those lock nuts too? Yes

I designed torque arms in SketchUP then exported to dwg and get the machine shop to do the laser cutting
Torque arm:

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

Torque arm with dimensions:

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

 

[Bazaki]

Thanks Joe,

Then you also should have the Lyen software, I found a second program which allows me to give much more amp.

Lyen-en.exe or something, amazing what a difference between 57a or 75a

 

[El_Steak]

Just stumbled on this...

Suberb build ! This is one of the cleanest most well executed build I've seen so far ! Your battery enclosure is really neat.

 

[GCinDC]

How's the ride? What's new? Any problems? Move video?

 

[torqueon]

I wish i could do the same, you Show off , keep it coming. Love good ideas

 

[JoeFR]

Hi GCinDC

How's the ride?
The ride is parked in the garage because we still have very cold weather ( -5 to 3 °C ) and I am waiting for warmer weather.

What's new?
I buy new tires Schwalbe Big Apple, I will change the rims for strong DH rims, and I am working on X5 motor air cooling.

Any problems?
Motor overheating, I have to drill some holes in X5 covers and change those wobbly rims

More video?
I will post pictures of changes and make some new videos as soon the temp... rises

Hi Nice
Thanks

 

[JoeFR]

Finaly some warmer weather came and I could take E-bike out

But first I made some modification during cold weather
Air cooling X5305:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/X5305_AirCooling_1.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/X5305_AirCooling_2.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/X5305_AirCooling_3.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/X5305_AirCooling_4.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/X5305_AirCooling_5.jpg

Change tires for Scwalbe Big Apple:

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/Schwalbe_BigApple_1.jpg

http://i920.photobucket.com/albums/ad43/JoeFR/E-Bike_ES/Schwalbe_BigApple_2.jpg

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

And record two new videos:
[youtube]i7WRnwfX9Ds[/youtube]
http://www.youtube.com/watch?v=i7WRnwfX9Ds

[youtube]jl2ZW2TaHHw[/youtube]
http://www.youtube.com/watch?v=jl2ZW2TaHHw

 

[AussieJester]

Nice ride there JoeFR i was also curious how you got the 'altitude speed and the lil gps? ' graphic in your videos, which also are very neat...Bike goes very well.

KiM

 

[JoeFR]

Hi AussieJester

I used this nice program:
http://www.dashware.net/

 

[JoeFR]

Because weather forecast is bad again I quickly record two more videos

Climb
[youtube]pGMP7A9R7kI[/youtube]
http://www.youtube.com/watch?v=pGMP7A9R7kI

Downhill
[youtube]WJHBvQxa7kc[/youtube]
http://www.youtube.com/watch?v=WJHBvQxa7kc

 

[AussieJester]

Hi AussieJester

I used this nice program:
http://www.dashware.net/

Thanks mate, shall see if i can 'find' me a copy

KiM

 

[2wheels]

That's a tight build....what was the total cost and time investment?

 

[JoeFR]

Hi 2wheels

Here is the pdf file with all the costs, included customs, tax, postal charges:
View attachment E-Bike_ScottAspect_Cost.pdf

I invest a lot of time in reading the ES forum and then build the E-bike step by step.

 

[JoeFR]

450 cyclists and one E-Bike

Common Start:
[youtube]bXrYyDVTONM[/youtube]

Hill Climb Start:
[youtube]nQmoqDKPIUA[/youtube]

 

[beast775]

holy hill climb! .tell me you were pedalling :lol: .awesome vids. you can get breathable cloth that is waterproof,just in case ya wanna make some round little covers for the drilled holes.

 

[JoeFR]

Hi beast775

Yes this time I was pedalling, because motor temp was high from instant hard accelerations.
I have waterproof tape in my backpack all the time in case of rain.

 

[doc007]

WOW That 2nd video was probably the best video Ive seen yet of an ebike overtaking road bikes. Nice!

 

[NeilP]

Just found your build..I was going to say that your box is almost an exact copy of mine...then i saw the posting date...mine is almost an exact copy of yours.

Mine is not finished yet, as I must first get my Lyen controller back and fit it properly. Pictured is a 48 amp Crystalyte controller, that is physically bigger than the Lyen controller

I did not go with so many batteries. I only went to 20 s 84 volt with 10s Nano Tech Lipo's ...but I have to remove my pack every day to bring in to the apartment to charge.

Very neat build, wish i could have done mine as well

I did not have the ability or facilities to get laser cutting or any sort of CAD machining done here on the island, so my torque plates were cut with grinder , drill and file.

I like the d sub connector for the balance leads. Can you still remove the packs individually or are the balance leads all hard wired to the d-sub?.

I did have a tppacks LVC parallel board, but had to remove it due to space ...I wanted to fit the controller inside the box...might have to consider your solution and fit external...but worried about waterproofing. I have to ride every day , rain or not

Neil

 

[JoeFR]

Hi Neil

Your box looks very nice. Mine is covered with carbon fiber look film to keep it discrete ( no shining aluminium ).

Your hand made torque plates looks very good too.

Can you still remove the packs individually or are the balance leads all hard wired to the d-sub?
I dont need open the battery box. I will open it at the end of the season to check if all packs are OK. The balance leads are connected with original connector to LVC board and then LVC board is connected to D-sub connector. I have all connectors needed to balance charge and bulk charge on the frame of the battery box, so no need to open it.

I use this setup for balance charging each of the 6S4P Li-Po battery packs. I am now working on 100V bulk charger with two 48V MW power supplys:

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

 

[NeilP]

I went for Stainless steel for my box, as I was not going to cover it...have gone slightly more forward in the frame, right up to the front triangle as a point,

I must take the batteries out to charge when I am home, so that limited my options a bit. i did not want to be parking the bike in my farm workshop and walking home, especially with having an early start again the next morning

I have the same iCharger and also use two Meanwells too, both S-350-48's I have mine setup so i can switch between series and parallel, and also have switchable voltage and current limit.
Also I have a tppacks cc/cv board, that switches out of the system when the Meanwells are in parallel

I have two 4 pole switches.
One is connected to 8 multiturn 5k cermet trimmer potentiometers. 4 connected to each Meanwell...2 replace the SVR1 voltage pot, and 2 replace the SVR2 current limit Pot. This switches between 41.5 volt and 8 amp current limit and 37 volt and 9 amp current limit

The other 4 pole switch, changes the output between Series ( and cc/cv board for bulk charging) and parallel for running the Meanwell. There is also a small switch to remove power from the cc/cv board and disconnect the sense line from cc/cv board to the resistor on the meanwell

Click for bigger image

For Bulk charging with more power Doctorbass is using this method

His image

See this thread
http://endless-sphere.com/forums/viewtopic.php?f=14&t=28275

For Free bulk charging I am trying this with PC power supplies...I can get loads of them for free, and space in the workshop is not an issue...so if I use the 5 volt lines, I can make a 2.5 - 3.0kW charger for nothing...

http://endless-sphere.com/forums/viewtopic.php?f=14&t=28632

http://endless-sphere.com/forums/viewtopic.php?f=14&t=8357


Although now these are available

http://www.bmsbattery.com/alloy-shell/164-alloy-shell-2000w-lifepo4li-ionlead-acid-battery-ev-charger.html

http://endless-sphere.com/forums/viewtopic.php?uid=18071&f=14&t=29096&start=0

it seems rather pointless building a bulk charger from Meanwells

 

[JoeFR]

Hi Neil

I see you make a lot of studying on battery charging

You have a great setup for charging. I am making something smaller so I can put in backpack and carry with me on very long rides.

I will post pictures when I am finished.