GCinDC's Giant DH Comp

make that stuff good and strong guys... I had a hall throttle malfunction at an intersection today. my worst nightmare.not cool! the ebrake was the thing that saved me. :)
 
GCinDC said:
smoke came out of bms battery charger... :roll:
20140406_100532.jpg
Click to expand...

axel told me he'd seen smoke when he used the charger but had no problems when he connected it to a powerstrip first and turned that on.

i didn't see how that could make a difference, but went ahead and tried it anyway...
[youtube]Mg6ATS3x8Rs[/youtube]

had to rush in to work so no time to examine it more closely. never heard a pop like that w/ just bad connections.

may be time to order a new one for him and a backup for me! :shock:

sorry, axel! i guess you can balance charge until that one gets fixed for the new one arrives (by June? :roll: )
 
ridethelightning said:
make that stuff good and strong guys... I had a hall throttle malfunction at an intersection today. my worst nightmare.not cool! the ebrake was the thing that saved me. :)
Click to expand...
my worst nightmare are the forks or my seat breaking at full speed, but nevermind that. sounds very uncool. why the malfunction? so glad you're ok!
 
GCinDC said:
ridethelightning said:
make that stuff good and strong guys... I had a hall throttle malfunction at an intersection today. my worst nightmare.not cool! the ebrake was the thing that saved me. :)
Click to expand...
my worst nightmare are the forks or my seat breaking at full speed, but nevermind that. sounds very uncool. why the malfunction? so glad you're ok!
Click to expand...


i think iv isolated it as the cheap hall throttle with 3spd switch from em3ev. i had a brand new spare that i substituted and the problem stopped.

on my dodgy work bike in the morning on the way to work when it happened.
the throttle was permenantly ON at its full closed position :shock:

so as i came to the intersection to wait for a brake in the traffic and all of a sudden!....couldnt stop!!!!

luckily i wasnt exactly perpendicular to the road and managed to steer along the side. the throttle was like set in cruise at 10amps! the ebrake/regen switch stopped it though,but i had to hold it down until i turned off the controller.

the odd thing is there is an "off" band if i open the throttle a bit, then it ramps up from there. its almost as if the positioning of the magnet or hall is moved over a bit.

ill open it when iv got time and check it out.
 
mine (good) on bottom. axel's on top:
20140410_214612.jpg


area on mine behind AC connector:
20140410_214544.jpg


and behind axel's AC connector and i'm holding part that popped off. they look like wires in the pic but they more like discs soldered to the board w/ two prongs?
20140410_214518.jpg


another pic of it:
20140410_215012.jpg


fuse looks fine:
20140410_214756.jpg
 
Pendragon is right. That looks like the NTC thermistors which limit the inrush current at start up, then warm up and their resistance drops. The fuse being intact is hopefully a sign nothing else is fried.

Dnmun may have replacements.
 
Yeah very likely inrush limiters, they always pop. You can test it by shorting out what remains of the parts legs (if it reaches just bend together and drop a blob of solder on them) You'll potentially get a bit more zap when you plug it in but if it works there's your answer. Dodgy brothers ghetto electrical at your disposal once again :p

I did this on my charger at work when it failed (didnt feel like pedalling home!) and 6 months of near daily use later it's still fine. As an aside, since rewiring my workshop around about the same time (~6 months) I very rarely turn my home charger off. More out of laziness (charger is bolted to the underside of a shelf and switch not easily accessable - the cord dangles out at the level where my bike leans and charges) but if you're not worried about some random component failure causing it to burn your house down (perhaps a touchy subject :p ) it's an interesting data point.
 
i will send you three more. i have some 6.3A ICLs i sell for the Vpower chargers. either you or axle will have to take it apart in order to solder the new ones in. send me your address again.

or send it out here if you wanna. i have two chargers here now i am putting back together or analyzing for others now too.
 
GCinDC said:
time to whip up a frame bag:
Click to expand...

That's awesome Greg, what material is it and where do you get it, i'm thinking of doing something similar.

I know you've mentioned it before but where does the metal section come from, i went to Menards recently and couldn't see it (not that i was looking very hard)
 
GCinDC said:
I'd check out local stores before buying anything online.
Click to expand...

Thanks Greg, i'll do some research and see what i can find. :D
 
dnmun said:
you can get the plastic fence rails in lengths also and then rip it along the middle of each side to make two pieces with the same C section for constructing the frame too.
Click to expand...
yeah, i made this for a fender out of kydex, and looked at it instead of the metal stud for axel, but after molded, it's not as flexible (to open like my metal frame):
20140309_152648.jpg


but i think a sweet frame box could be made out of a full sheet of it, and then you wouldn't need the fabric..
 
Thanks guys i have some inspiration now to look into this. I currently have a em3ev bag which is great but pretty limited on how much can go in it, i've actually considered sewing two of those bags together which would work but i have other projects that i'd like to use them on. I think i'll knock up a build thread over the weekend, its been a long time coming anyway!
 
GCinDC said:
dnmun said:
you can get the plastic fence rails in lengths also and then rip it along the middle of each side to make two pieces with the same C section for constructing the frame too.
Click to expand...
yeah, i made this for a fender out of kydex, and looked at it instead of the metal stud for axel, but after molded, it's not as flexible (to open like my metal frame):
20140309_152648.jpg


but i think a sweet frame box could be made out of a full sheet of it, and then you wouldn't need the fabric..
Click to expand...

I got away with abs sheets-super easy to work with- but kydex should be even better!
 
ridethelightning said:
GCinDC said:
ridethelightning said:
make that stuff good and strong guys... I had a hall throttle malfunction at an intersection today. my worst nightmare.not cool! the ebrake was the thing that saved me. :)
Click to expand...
my worst nightmare are the forks or my seat breaking at full speed, but nevermind that. sounds very uncool. why the malfunction? so glad you're ok!
Click to expand...


i think iv isolated it as the cheap hall throttle with 3spd switch from em3ev. i had a brand new spare that i substituted and the problem stopped.

on my dodgy work bike in the morning on the way to work when it happened.
the throttle was permenantly ON at its full closed position :shock:

so as i came to the intersection to wait for a brake in the traffic and all of a sudden!....couldnt stop!!!!

luckily i wasnt exactly perpendicular to the road and managed to steer along the side. the throttle was like set in cruise at 10amps! the ebrake/regen switch stopped it though,but i had to hold it down until i turned off the controller.

the odd thing is there is an "off" band if i open the throttle a bit, then it ramps up from there. its almost as if the positioning of the magnet or hall is moved over a bit.

ill open it when iv got time and check it out.
Click to expand...
so this is what happened-


i often let the throttle snap back closed while riding. i think repeatedly doing this(for 6 months or so) has caused the small plastic stop to break off.

allowing the sliding magnet to rotate too far at closed position.

this gave me a unexpected 500 watts of unstoppable power before i finally realised what was happening and hit the ebrake switch :shock:
 

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had a spare BMSbattery charger. was set to 100V but easy enough to drop to 83.5V (sped up):
[youtube]jpb4n__M9dk[/youtube]

and with that on loan, the customer took delivery by moonlight:
20140412_202927.jpg


and i've been getting some emails with lots of smiles. how does it feel axel?
 
dan974 said:
I did not got how much you were able to fit ? 20s? How much packs, I m pretty impress how clean it goes...congrats
Click to expand...
8 x 5s 5ah packs. we'll have to see how hot that controller gets in there, esp come summer. he can either manage his throttle, lower the current or install heatsink/fans. we'll see.

just created a thread for his new baby: Axel's Giant DH Comp
 
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