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Heavyweight 12kW Commuter

striker54

100 W
Joined
Jun 25, 2013
Messages
270
Location
Portugal
Hello guys,

I didn't made a thread about the first build but I will summarize a bit.
No-suspension MTB steel frame with a front hub 9C 2807 powered by a 36V20Ah LiFePo4 battery
Max speed: 28km/h (17.4mph) no pedal
After 1500km of commuting i start "needing" for more power, so I found this wonderful forum and start to search:
• bought a 12fet IRFB4110 40A infineon controller plus a CA DPS v2.3 from EM3EV and another 36V20Ah battery.
• In the motor i installed a temperature sensor and upgraded the phase wires to 10AWG and ready to oil cooling.
IMG_0059.jpgView attachment 10

Max speed (no pedal): 54km/h (33.5mph) :twisted:
Now I was getting a good speed and torque but after some tests I realize that the front hub with all this power was more unpredictable and all the additional weight of the second battery with a non-suspension bike will lead to some serious injury. :cry:



So it’s time for a second build:
More clean :wink:
More powerful :twisted:
More safe :roll: (if possible) :twisted:


After a lot of reading i have decided the major components:
• Vector frame (aka e-kross)
• Cromotor v3 laced in 17” moto rim with a shinko SR241 3” wide
• Adaptto Max-E with BMS + 70A coil
• HK lipo Multistar 22S 40Ah
• DNM USD-8 suspension with dual disc brake
• Tektro dual disc brakes with 203mm rotor
• DNM RCP-Burner 2 shock
• 26” front bicycle rim (for now)


This will be a heavy bike (+/- 65kg / 143 pounds) but hopefully with a lot of torque :twisted:

View attachment 9
After the frame arrived I installed the headset following some DIY videos on youtube and managed to mount the very tight swingarm on the frame.

Cromotor laced and tire installed
DSC05409.jpgDSC05407.jpg

Cromotor installed on frame and freewheel clearance check:
DSC05428.jpg

Suspension and front tire installed on frame:
DSC05438.jpg

Capacity check inside the frame for all the lipo:
DSC05418.jpg

I’m going to need some spacers to make the frame a little wider:
DSC05420.jpg

Start drilling and routing all the wires:
View attachment 2
DSC05442.jpg

Thumb throttle for variable regenerative braking:
DSC05440.jpg
 
Nice bike and great component choice. Final weight seems quite heavy, I would think it would come in a little lighter than that. Should have some quite ridiculous range! 120km at my average consumption with Adaptto/Cro. You should get some excellent lifespan out of those batteries as they certainly won't be stressed with that pack size and you won't need to charge >4.1v. Good stuff!
 
Here a more detailed look at the weight of the components:
Cromotor with rim and tire -> +/- 18kg (39.6lbs)
Battery with enclosure and cables -> +/- 19kg (41.8lbs)
Front fork with rim tire -> +/- 8kg (17.6lbs)
Only frame -> +/- 11.5kg (25.3lbs)
All the others minor things (cables, brakes, mudguards, chain, pedals, etc) -> +/- 8kg (17.6lbs)

I could save some weight if i choose:
• a narrow rear tire
• 18650 battery and/or a little Ah less
 
Ohbse said:
Nice bike and great component choice. Final weight seems quite heavy, I would think it would come in a little lighter than that. Should have some quite ridiculous range! 120km at my average consumption with Adaptto/Cro. You should get some excellent lifespan out of those batteries as they certainly won't be stressed with that pack size and you won't need to charge >4.1v. Good stuff!

Yes, the idea is to never need to charge above 4.1V and not stress the cells.
For now i'm getting an average of 36Wh/km because i can't control myself :twisted:
it's very excitting to see other people with the face: :shock:
But i know for sure that i can get lower value if i control the throttle.
 
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