Magic Pie 4 (Vector) conversion build

[voltaj]

I hope this would help others build their Magic Pie e-bikes and also help me get some answers
Before photo:

A ~5 year old Schwinn bike from Costco with 26" wheels.
All the parts I got from goldenmotor.ca

48V10AH LiFePO4 Aluminum Cased Battery
Seatpost Battery Rack
Rear Torque Arm
USB Programming Cable for Magic Pie 4 VECTOR and Smart Pie 4 VECTOR Controllers
Magic Pie 4 (VECTOR) 24 Inch Rear Conversion Kit (Throttle: 48 Volt Twist)

Challenges:
1) The parts come with ZERO instructions! :x Assembling the seatpost battery rack is gonna take some guessing since I cant even find a clear photo of it assembled online.
2) I cannot replace my brake levers because they're one piece with the shifters:
So I might get the hidden wire brake sensors http://www.greenbikekit.com/hidden-wire-brake-sensor.html
I wonder if they're reliable to cut off the power and compatible with magic pie.
3) I want a half twist throttle, not available from golden motor so I'll have to shorten this one:

What is the widest tire that would fit on this rim?

 

[voltaj]

The Golden Motor battery rack RAK-002 assembled:
The seatpost was not straight (the holes for the battery plate wouldn't fit) and required some bending. Some of the screws are a little too long.
The support struts for the battery rack are supposed to be fitted to the seat clamp bolt.

 

[voltaj]

Original disk break screws were too long, hitting the controller. Using washers is not an option because the screw heads will hit the motor cable. I had to shorten them about 3mm.View attachment 11very important to use this washer otherwise the flywheel will lock up on the wheelView attachment 9for an 8 speed flywheel you need 3 spacer washersView attachment 8It's much more comfortable holding a half throttle for longer periods of time A temporary solution for using regen ebrakeView attachment 5extra cable hidden in a pouchrear torque arm V4View attachment 2This is how I decided to mount the battery support, because I didn't want to have it on the seatpost (too high, and it's annoying to adjust the seat height). I had to bend it a little bit more to make sure the wheel doesn't rub on it.
Bike almost finished, very happy with the performance

 

[voltaj]

For the ebrake levers I decided to use reed switches normally closed. The smallest I could find are the MK24 (type B are normally closed):
http://www.meder.com/fileadmin/meder/pdf/en/For_Showroom/PS201008_MK24_Series.pdf
order here: ($7/piece)
http://www.digikey.com/product-detail/en/MK24-B-2-OE/374-1136-1-ND/2421995

 

[voltaj]

The Mk-24 B reed switches are really small
I used buckyballs magnets. They only work in a certain position, find the right magnetic pole and the best position.
Test:
https://vid.me/zBZn

 

[voltaj]

Finished:View attachment 1