Giant Reign 2 Completed

[Thecopterdr]

Ok I finally got the battery pack sorted.
So far I haven't had any issues regarding losses with the long lead. I have a 50 cm lead coming up from the speed controller and 75cm lead from the pack, All 10 AWG wired with EC5 Connectors.
I still have to be careful when opening the tap as the front wheel wants to come up in the bottom 3 gears.
Fitting a CA soon to monitor amps and consumption - Video to follow very soon.




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[DeepSouth]

Thanks for posting Photo's Thecopterdr nothing's going to happen to your lipo. I'm still using my cardboard special rapped in a towel. Flat out busy with the lead up to Xmas, everybody wants things done now. Havn't had time to do anything, I did find time go up into the hill's for a ride Late Saturday afternoon. Love it, this is my first ebike. Did have issues, all to do with how twitchy the throttle is. Move it a mm or so and suddenly you have all that torque on line, very different from riding a trail bike. Very early on I was doing a steep decent down a gravelly track, I shifted my weight as I went round a sharp bend inadvertently tweaked the throttle and was dumped straight over the handle bars flat on my face. My body did a good job of protecting the lipo . Gave My left elbow and knee a really good rap, ignored them and carried on riding. Soon after I did another step decent about thirty meters over rocks, this time I disconnected the battery before I even started down. After another twenty minutes or so of riding I had to head back to the car as my elbow was killing me. A Very unpleasant twenty minute ride on steep tracks only able to use the front brakes. Didn't have enough strength in my left hand my that stage to use my back brakes. The only postive was that my elbow hurt so much I hardly noticed the pain in by Knee. Before I go out again going to buy some elbow and knee protectors. Back in the Nineties had a very similar spill and shattered my right elbow, it's held together now by pins and wire. Funnily enough it's just about the only joint I have that doesn't cause me problems.



Above is a mud map I draw up for making a battery case out of poly-carbonate. Don't know anything about working with Poly-Carbanate. Battery case's I have seen have been screw together, but the idea of a screw been popped in a crash and puncturing my lipo disturbs me. That's why I thought glueing and four threaded steel rods. I suppose if I wanted to get fussy and complicated I could drill and pin it, but I don't . Will decide on final dimensions when I have picked a new back pack, the one I have is a bit to big.
Your wire is heavier than mine, have ordered some 45 Amp Andersons and will make up new lead, but won't loose any sleep over it. I suspect those crappy thin little wires out of the motor are a bigger issue, all I have to do is get of the bike and shorten them.

This is very exciting, the first time I have been able to type since I did my elbow a definite improvement.

 

[Sirbevalot]

dr,

Thanks for thepics of your set up. I'm gonna do the same with my 12s 2p set up. Makes the bike cleaner and less bulky.

 

[bandaro]

love the build, the mount is awesome, nice and light and protects everything well. Only problem I have with it is the top of the right side plate, where you have the sharp angles cut so the motor/gearbox fits in?

As for the battery box, I would skip the polycarb as well, my suggestion is to make it from fibreglass, that way you can get it the exact size and shape you want without adding much weight and no screws. Better yet, you can have tiny wall thickness comparatively and rounded corners on the outside, making the whole package smaller and fit in a bag easier. Use a foam block in the shape of the batteries, wrap the glass around it then pull the foam out. You can use timber and stuff, but more tooling, so depends on your workshop access.

But very nice, love the compact size of a planetary.

 

[Thecopterdr]

Well its been a while since finishing the Reign 2, I have made quite a few changes and will share them in the next couple of days.
I'll post photos and hopefully they will save others from making similar mistakes. I also have some video yet to be edited.

 

[Sean9002]

Great build mate! Im glad i stumbled across it. Im in the process of planning my Giant reign/Cyclone build too. How do you find the bikes geometry with the extra weight?
Ive been looking at a dual motor setup but havent quite decided. What state are you in? im in VIctoria.
Looking forward to seeing your setup progress!!
-sean

 

[Thecopterdr]

Hi Sean, The extra weight is not that noticeable but the biggest thing I noticed was the flex in the swingarm if you apply too much power in a turn.
I've had to learn to ride the bike differently but its not hard. I'm on The Sunshine Coast where the trails are as rocky as hell.
I've been going out to our Mountain bike Trail park and riding on average about 2 hours, On measuring capacity back at the car I have between 40 and 50% remaining every time. A lot of the riding with power on has been up steep single track, Overall I'm very happy with duration Off road. On road its not so good but I can still get about 30kms per charge with the minimum 20% remaining.
I learnt that Aluminium mounts were not enough after the 3rd session out when the Motor free wheel locked up solid, it became evident that the mounts were twisting under load and mis aligning the drivetrain just enough to upset the freewheel bearing. I made a slight change and got 2 new Motor mount sets water cut out of 314 Stainless Steel.... Zero movement now.
Other changes include A thumb Throttle instead of the half grip twist, I found it hard on the right arm to hold on with 3 fingers while I twisted throttle with thumb and index finger Especially when climbing steep terrain.
I'll post photos of the changes when I can In the next few days. If anybody is interested, I can print up the Controller mounts, Battery pack strap supports and Freewheel cap on the 3D printer. I also have a spare set of 314 Stainless motor mounts ready to go.

 

[rodgah]

.... The Sunshine Coast... .

QLD?

I live in Caloundra.

 

[Sean9002]

If anybody is interested, I can print up the Controller mounts, Battery pack strap supports and Freewheel cap on the 3D printer. I also have a spare set of 314 Stainless motor mounts ready to go.

I may be keen to buy a few bits once i get further along!
Im down in vic so our trails are vastly different to yours. Especially around the Otways, loose packed and muddy =)

 

[Thecopterdr]

Well I thought i'd post some updated pictures.
I am offering a custom building service to anybody who wants a similar framed bike done.
I have completed a 2010 Giant XTR29er and now this Giant Reign 2012 using the same principles and ideas.
This bike is now at the point where I am completely happy with it as I have been able to weed out the weaknesses and little issues that creep into a build once you get a few sessions in.

The Copterdr

 

[Thecopterdr]

I had forgotten to mention that I have also thrown the original Cyclone bottom bracket in the bin - It was responsible for a fair bit of wobble in the drivetrain and I have fitted the new Cyclone 148mm ISIS bottom bracket and cranks. This has removed the "cheap" feel of the bottom end as it runs true, doesn't flex and is considerably stronger than the original.
I recommend it to anyone looking for a solid bottom end option.

 

[andrenoites]

Thecopterdr:

Very nice setup. If you want a more discrete ebike you could remove the engine cooling fins. I bet the temperature will stay in a safe interval.

For the 55Km/h what's the drivetrain you are using? 11T back with 42T front? is the engine chainwheel 48T?

Tks
André

ps: the controller could be isolated and fitted in the bottom of the frame behind the chainwheel. It will make a huge difference in esthetic

 

[Thecopterdr]

Very nice setup. If you want a more discrete ebike you could remove the engine cooling fins. I bet the temperature will stay in a safe interval.

For the 55Km/h what's the drivetrain you are using? 11T back with 42T front? is the engine chainwheel 48T?

Tks
André

ps: the controller could be isolated and fitted in the bottom of the frame behind the chainwheel. It will make a huge difference in esthetic /quote]

Andre
Thanks, the Controller was fitted in its location because Mud buildup is a problem in that area along with the large amount of travel from the swingarm. When looking at the photo you'll see there simply is no room for a controller and its wiring in that location anyway, I think having the motor above the down tube is unique for this style of mid drive anyway - I tried to to keep it as clean and discreet as possible.
I get about 67kmh top speed, unfortunately the White industries Eno freewheels don't go smaller than 16 tooth and all the other brands just don't last.
So motor is 16t chainwheel is 44t, inner chainring is 32t and whatever gear is selected for the final. I still find that the motor will overtemp in top gear if you have the throttle wide open. Just trying to use as much stock gearing as possible.
As for the cooling fins.... you need them especially during the longer steeper single track climbs.
I still believe that it's very hard to make a bike that will do both street and off road very well. I'm looking into a hub motor to do a dedicated street bike, but know that hub motors as quiet and simple as they are just overheat too easily offroad.

 

[Thecopterdr]

A few more mods after another 6 months of riding.
White Industries Eno Freewheel on the motor
Thumb throttle
Rounded off the cooling fins (no more bleeding leg)
304 Stainless Steel motor mounts
New supportive battery pack setup

6 months of abuse and this thing is bulletproof, Chain never comes off, Motor never overheats in anything below top gear, Battery pack handles huge wipeouts with ease (over the handlebars on rocks and gravel) Rider not so durable, Zero flex in the motor mount arrangement, The Eno is still as tight and crisp as the day I brought it.

 

[jollydet]

what bottom bracket setup are you using? as i thought the reigns had press fit shimano bottom brackets? fantastic build by the way

 

[Thecopterdr]

Bottom Bracket is 148mm ISIS, The one that Cyclone make. The standard ones are just junk.

 

[jollydet]

ok good to know the isis bottom bracket fits, i thought the reigns had a press fit bottom bracket , maybe it was just the faiths, unless you did something custom to fit it?

 

[jateureka]

That's a neat mid-drive build.