electraflyit
10 W
My original ebike frame was an ebay ‘Special’ I built up, so I thought before I kill myself I’d better upgrade to a decent bike. I wanted a strong frame, good suspension and large hydraulic disk brakes. I found a well used but mechanically good Kona Stinky for the right price that had it all.
I wanted to be able to pedal along at a reasonable pace so I needed to remove the bash ring and replaced it with a 44 tooth chain ring. I also ordered an IRD 5 speed freewheel 11/32 to replace the old 14/28 original on the GM hub.
Build Parts:
Kona Stinky Down Hill, GM1000 Hub, Ping 48volt 20amp battery, 6 Fet programmable controller, CA , Multi switch, Marvic rim, SS spokes, IRD freewheel,
44 tooth chain ring, SRAM chain.
I was looking for a simple and clean layout.
I had a little fun trying to get clearance for the shifters with the throttle and multi switch.
Green momentary button(horn) – Regen/Brake
Red button(lights) – Cruise control
Blinker switch – Speed 1, 2 & 3 switch
I moulded up a Fibreglass battery box just big enough to fit the Ping 48v 20a.
The weight is on the border line for the beam mount. It’s rated at 10kg and I’m at about 12kg.
I think the FS frame will help take out any sharp loads on it (I hope)
I know….the seat….anyone know/recommend a comfier one.
Scoops for exhaust air.
I had a small glider mould so I just used it to make the two fiber glass scoops on top and front of the battery box.
View attachment 6
Jiffy box for all the connectors/connections and a mount for the ESC 6 fet (with updated fets). Marine quality circuit breaker, precharge button and Charge port.
Kept the wiring black and put the motor wires in black snake skin, sort of hides it pretty well.
Would have loved to have kept the Hydraulic rear brake but it was just to thick to fit.
The 200mm rotor was helpful in getting the calliper to fit…sort of…clearance from the disk to swing arm is 1 to 1.5mm and about the same for the calliper to the hub.
The screw on disk adaptor….that’s another story…#^^#*@%* threads*^%*$*(
I ground the Caliper back(hub side) and the caliper mount to get things to fit.
I had two 1/4'†steel torque arms that I repurposed/reshaped to fit the dropouts and lock in.
I have brand new IRD and Shimano(both better gearing and quality) freewheels that sit quietly in their boxes while I pulled apart the old one and, cleaned, regreased, shimmed and put it back on the hub ….. *(^%%($# …….GM threads on this motor aren’t standard. Two to three turns with the new freewheels then stop..., no, not cross threaded….no easy way out just had to put the old one back on.
My first wheel build, ended up really good…..until my first few rides. I built up a new rear wheel with a Marvic rim with 13/14 gauge SS spokes. I knew they would loosen up a bit…..but…..that much (a little buckle)?? Anyway their retightened now, just a bit worried with the amount of bend on the spokes coming out of the nipples. Maybe I should have done a radial (straight) pattern instead. YES/NO??
The maxis hookworms seem like a great tyre, they look good and you can really lay the bike over now….great cornering traction, handles more like a motorbike.
Next:
I’m in the process of building a FG mount for a GPS to sit on the bars.
Also waiting on some Lipos, only 14s 5amp, just to check them out, see how many I can get in the triangle, check out the charging and lifespan. Also a bit of backup on my long rides.
Eddie
TBC
I wanted to be able to pedal along at a reasonable pace so I needed to remove the bash ring and replaced it with a 44 tooth chain ring. I also ordered an IRD 5 speed freewheel 11/32 to replace the old 14/28 original on the GM hub.
Build Parts:
Kona Stinky Down Hill, GM1000 Hub, Ping 48volt 20amp battery, 6 Fet programmable controller, CA , Multi switch, Marvic rim, SS spokes, IRD freewheel,
44 tooth chain ring, SRAM chain.
I was looking for a simple and clean layout.
I had a little fun trying to get clearance for the shifters with the throttle and multi switch.
Green momentary button(horn) – Regen/Brake
Red button(lights) – Cruise control
Blinker switch – Speed 1, 2 & 3 switch
I moulded up a Fibreglass battery box just big enough to fit the Ping 48v 20a.
The weight is on the border line for the beam mount. It’s rated at 10kg and I’m at about 12kg.
I think the FS frame will help take out any sharp loads on it (I hope)
I know….the seat….anyone know/recommend a comfier one.
Scoops for exhaust air.
I had a small glider mould so I just used it to make the two fiber glass scoops on top and front of the battery box.
View attachment 6
Jiffy box for all the connectors/connections and a mount for the ESC 6 fet (with updated fets). Marine quality circuit breaker, precharge button and Charge port.
Kept the wiring black and put the motor wires in black snake skin, sort of hides it pretty well.
Would have loved to have kept the Hydraulic rear brake but it was just to thick to fit.
The 200mm rotor was helpful in getting the calliper to fit…sort of…clearance from the disk to swing arm is 1 to 1.5mm and about the same for the calliper to the hub.
The screw on disk adaptor….that’s another story…#^^#*@%* threads*^%*$*(
I ground the Caliper back(hub side) and the caliper mount to get things to fit.
I had two 1/4'†steel torque arms that I repurposed/reshaped to fit the dropouts and lock in.
I have brand new IRD and Shimano(both better gearing and quality) freewheels that sit quietly in their boxes while I pulled apart the old one and, cleaned, regreased, shimmed and put it back on the hub ….. *(^%%($# …….GM threads on this motor aren’t standard. Two to three turns with the new freewheels then stop..., no, not cross threaded….no easy way out just had to put the old one back on.
My first wheel build, ended up really good…..until my first few rides. I built up a new rear wheel with a Marvic rim with 13/14 gauge SS spokes. I knew they would loosen up a bit…..but…..that much (a little buckle)?? Anyway their retightened now, just a bit worried with the amount of bend on the spokes coming out of the nipples. Maybe I should have done a radial (straight) pattern instead. YES/NO??
The maxis hookworms seem like a great tyre, they look good and you can really lay the bike over now….great cornering traction, handles more like a motorbike.
Next:
I’m in the process of building a FG mount for a GPS to sit on the bars.
Also waiting on some Lipos, only 14s 5amp, just to check them out, see how many I can get in the triangle, check out the charging and lifespan. Also a bit of backup on my long rides.
Eddie
TBC