Hillzofvalp's 29er Thread... now with custom 63T (cromotor)

[hillzofvalp]

Holy shit. Fast bike. I have the circumference set to about pi*28.5" instead of pi*29" on the CA in order to account for tire compression. I need to calibrate, but the CA was telling me I was doing 40mph at one point. It felt like 40. Scary. I want to get some 700c ebike rated tires, but the only ones I can find are like 38c. I want big tires like these 2.35" big apples. I wonder if a smaller rim with a bigger 26" tire could reach the same diameter as say a 38C 700c tire. I have a big frame that may take a fairly wide tire.

The torque plate extension seems to be holding up well. I added two bolts for insurance. The pinch actually separated some of the epoxy, so now I'm only very lightly pinching it.

I was talking to my friend and was distracted-- I made the mistake of plugging in the "power key" one slot over, which effectively shorted one half of my pack. The connector termination vaporized before the 100A fuse tripped. Luckily, the damaged female receptacle is just a charging port, and I shouldn't have to redo the contacts unless I decide to put in some serious bulk charge current.

I'm in the process of redoing the panels. One more to go. I plan on trimming off all excess aluminum. I'm pleased with the appearance. I hope you like it to. The reduction of the panels will make it look more like a normal bike (with tubes present). I am looking into printing off fake water bottle cages and water bottles for an effect .

I decided to route the phase wires through the bottom of the enclosure so that precipitation cannot dribble into the controller from above. This will also make sealing the top corner of the enclosure much easier.

I'm exploring adding some removable, screened scoops that throw air at the controller in hot, dry weather. These can also function as ports for accessing programing cable and checking get temperatures without having to take all 20 screws out.

I will upload a video soon of it in action. CAn't wait for cromotor. This 9C is going to burn up (and I'm glad it is). If I don't like the performance with this 12 FET and the cromotor, I will try to make a heat pipe or something that pops out of the enclosure so I can run it at 60-80A at 66V. 140A phase.

 

[Haste]

Bike looks great, how do you like the simple Plug in and forget about it a123s? Any idea how much you have invested in the batts?

 

[hillzofvalp]

Lets see:

2x 8s dewalt packs $130
54 raw cells: $220
30 extra (free)
Tried to build tab welder but haven't worked out kinks ($100)
2 rolls of Nickel tab $50
Batteries plus labor $100
8 gauge wire $25
Molex connectors (free)
3d print connector mount $10
2 Hyperion 1420i ($120 + 180)

Probably around $600-700 not including the tab welder or chargers. I'm also working on a 25A-35A bulk charger

Soon though I will have to add some of that circuit board material (d10?) betwenen the packs to minimize ability of fire to spread or got spots to short out against adjacent packs.
.


Time: too much

 

[hillzofvalp]

Cromotor down payment has been made. Buying a motor that costs as much as my batteries really lacks rationalization. I will have much peace of mind though with 4kW continuous rating.

Currently I am doing finishing touches on the revised edition of my triangle enclosure. Per recommendation and from my existing interest in trying to paint behind the clear polycarbonate, I tried it on one side with matte black. It looks phenomenal. I will leave the other side clear temporarily for trouble shooting and testing. I also screwed it up when I milled it out so I'll be making another set probably for $25.

I will post pictures this weekend after I have it all done. I still will have a lot of work to do closing up the top portions from precipitation (which I won't address for some time cause I want it to WORK!)

Meanwhile I've been riding a mini bike to campus. This is my friend on the Turnigy 80-100 variation.

 

[MadRhino]

Switching from this to a 29er, you will feel like a giant. :lol:

 

[hillzofvalp]

Yeah, this 29er really makes you feel like you're flying/hovering.

I forgot to mention that I must discuss my cromotor wheel build! rhyno lite 36mm rim? Stick with 24mm velocity chukker? 12 gauge spokes adequate?

 

[MadRhino]

I find a Rhino Lite a little weak for 12 Ga spokes, especially with a big motor as this one.
That is my choice for a 29er

 

[hillzofvalp]

Nice. What about tires? Schwalbe makes ebike rated tires but their only in 1.75" width x 28 diameter.. Energizer is what it called.. They have a super safe version too with extra material.. I assume these would fit. I have 2.35" big apples ATM but I worry about blow outs t 30mph.

 

[chroot]

Hi, You worried about your tire would blow up in high speed and I wanted tell you that I have been abused on Hookworm 26x2.5" tires. Of course, I commuter to work at 40 mph everyday. My spokes finally snapped and I sent to ilia's new shop. He replaced new Velocity rim, new spokes and I inspected inside the hookworm tires. WOW it still look brand new and nothing shredding or crack at all. Can you imagine! 40 mph everyday for 1 and half year. 8)

I don't know if the hookworm tires offer 2.5" wide for 29" wheel.

 

[MadRhino]

There is a very limited choice of big volume tires for 29ers. Where and how fast will you ride?

 

[hillzofvalp]

primarily familiar roads. up to 35-40 but mostly in 20-35mph range

 

[chroot]

All I can find is Schwalbe 29er has wide than what I can find.

I don't know if 28 vs 29 able fit on 29er rim?

Schwalbe Big Apple 28 x 2.35
Schwalbe Fat Frank 29 x 2.00

I looked the hookworm seems only offer up to 26" size, Cyclop CST 2.4" same only 26" max and many tires I looked mostly 1.75 or less.

Apparently MadRhino is right. 29er tires with wide size is very limited.

 

[MadRhino]

Maxxis Ikon XC Wire 29er 29 x 2.20
Try to find it in triple compound, but no folder. The wire bead is a must.
It will be noisy at first on pavement, but soon more quiet as it is wearing

Alternatively, the Panaracer Comet XC Hardpack 29 x 2.25
The wire beaded version, that Panaracer name Ridgid
More silent from the start, feels about the same as a Kenda Small block

 

[MadRhino]

I don't know if 28 vs 29 able fit on 29er rim?

The standard for 29ers is ETRO 55-622
Any tire that has this ETRO number on the sidewall does fit a 29er rim
if it has a different number, it may or may not fit, but for sure will be hard to mount. :wink:

 

[hillzofvalp]

It's beginning to look more sexy... But still lots of work to do to make it torrent proof. Took the 9c out today with shitty 2.5:1 pedaling ratio.. I need to make revision to my 11T freewheel adapter.. It I'll be getting a cromotorxo that won't even fit so I might forget about that modification. 9C gets vey gummy especially after stopping for a minute, cessating the air cooling. I don't know if I will paint the other side for some time because I want to be able to see any problems. A lot of wiring and a lot of cable management! Takes a lot of energy and strategy to fit all this in a 2" space. I'm already thinking about higher energy density cells and I haven't even put 30 cycles on this pack.. New cut off is 60V.. And cells were in 2.8-3V range pin lvc. So good.

 

[hillzofvalp]

I think for the next panels I'll do some sort of color scheme that matches the bike more.

Bike charges in 40-50min with dual hyperions at max output. I have to make sure though that the precharge switch at mid pack is off before I connect the leads. Does anyone know the best way to protect the chargers in the event the switch is accidentally turned on in net mode?

 

[hillzofvalp]

Thinking about a 26" rim instead.. what are good tires that equate to a 27-28" finished diameter in a 26" rim?

One day I put 40 miles on my bike. A lot of fun. Here is a pic of me in the middle of no where with no power left

 

[hillzofvalp]

I just may make a 63 tooth chainring so I can pedal at ~90rpm at 30mph. It would cost me about $40 to make it from .125" 7075 T6. I am doing away with the 11T freewheel coupler because the cromotor will not have any space. I wish I knew more MEs so they could critique my design. I'm sure I'll end up beefing it up more.

 

[BATFINK]

That chainring will be pretty intense. I've got a 52 tooth and think that's great. Great looking build. Well done

Sent using Endless-Sphere Mobile app

 

[hillzofvalp]

Well thanks. It's a fun yet challenging project at times. What is the largest 110bcd chainring? I may actually settle for a 55-60T

 

[shorza]

Thinking about a 26" rim instead.. what are good tires that equate to a 27-28" finished diameter in a 26" rim?

One day I put 40 miles on my bike. A lot of fun. Here is a pic of me in the middle of no where with no power left

Wow, how did you get home?

 

[hillzofvalp]

Moms mini van. I could've pedaled but I was wearing inappropriate clothes for the temperature.. Maybe 1.5 miles away. It ran out after 16 miles.. Not to be confused with 40 miles

 

[hillzofvalp]

Just read the spec sheet on these molex connectors.. and found out that they have a minimum cycle life of 200 cycles.

I am talking to them about a better low profile solution. Hopefully I can just bend the little female contacts back every few months and they will function normally.

Otherwise the bike has been great. I am currently speccing out my new cromotor wheel set. HEre's a post I copied from Facebook:

I wanted to try to use a front e-bike rated tire at a minimum. The Schwalbe Energizer Plus is one such tire. Comes in a 1.75" width and is a 47-622 tire that is best suited to a 25c rim. what's a good 700x25c or maybe 27 rim?

For the rear, for strength I was thinking initially an MTX33 with one of the 2.35" big apples I already have. However, then my bike will be slightly angled downward. I want to try to match the back wheel. Now I'm considering a 26" rear rim with a gigantic tire that will more closely match my front (with the energizer it would be roughly 2250 mm circumference). Hookworm would be a little small, but I'm not leaving it out. WHo makes good 26" tires for 25-40mph?

 

[Chalo]

Thinking about a 26" rim instead.. what are good tires that equate to a 27-28" finished diameter in a 26" rim?

I have a bike with 26x3.0 Kenda Kraze slicks on it, and they meet your criteria. However, those tires are too wide to fit in most frames, and I don't know where to buy them any more. The bike has 48 hole Snow Cat rims.

If 29er tires had been widely available when I built up the bike, I'd have used them instead. I'm still considering relacing to 29 inch Rhyno Lite or Kris Holm rims.

Rhyno Lites are available in 48 hole; Kris Holms are much stronger, heavier, and wider. I built my Redline 29er e-bike with Kris Holm rims, and I'm very happy with them. I don't think there is any reason to switch away from Chukkers for strength reasons, but wider rims do give a better, more stable shape to wide tires. When I de-electrified my Redline, I substituted a narrower Mavic T519 wheel in front (similar in width to the Chukker) because I had it handy, but the 700x60 Schwalbe Big Apple tire fits and feels much better on the 38mm wide Kris Holm wheel in back.

For this category of equipment, the strength is in the rims, not the spokes. The more spokes you have in the wheel, the thinner the spokes should be for best results. So my Redline with 36 spoke wheels has 13/14ga butted spokes in back, and 14ga straight gauge spokes in the front. The Bohemian MTB above has 14ga spokes in the back, and 14/17ga butted spokes in front. I have broken a couple of the 13/14ga spokes because of the oblique insertion angle into the rim, but I've not broken any of the other thinner spokes.

For what it's worth, I measure 6'8" and weigh about 325 pounds now, and I've regularly ridden both the bikes described when I weighed over 400 pounds. Both bikes weigh close to 40 pounds naked and the Redline weighed about 120 pounds electrified. So these wheels can take a beating without sacrificing reliability.

Chalo

 

[hillzofvalp]

Thanks for your input. I'll look into the Kenda and measure my frame. As is there is 6cm tire with
1cm gaps on each side.. So might actually work out since 26x3.0 max width is actually at a wider area of the frame, i believe. Are high speed rear tire failures just as dangerous as front failures? I would assume rear blowouts would be easier to recover from unless u were going around a turn.