Marin Muirwoods 29er Conversion - 48V Magic Pie II Build Log

layzbones

1 mW
Joined
Jun 15, 2015
Messages
15
Location
San Francisco, CA
Documenting my fist build here, been wanting to get into eBikes for a while now, and finally decided to pull the trigger after weeks of reading and head scratching. The purpose of the bike is mostly for joy riding around the city, having fun and learning the basics of the technology that's out there. I live in San Francisco where very step hills (the kind where they cut steps in the sidewalk) and strong headwinds are no joke, so a powerful rig is required.

We have a Faraday Porteur at work that we can take around the city for errands, which was my first exposure to E-bikes. Really liked the Faraday due to it's simplicity and smooth pedal assist (torque based). I'd like to set mine up with torque-based assist at some point, but going to start with throttle and eventually add a THUN bottom bracket torque sensor.

Hoping to keep the budget at less than $1500.

The Bike - 2012 Marin Muirwoods "29er" - I'm a huge fan of steel frames, big wheels, and this one is super stealthy and not covered in ugly logos. Picked it up on CL for $300 in great shape. Added fenders and replaced the tires with Geax Evolution 29er Tire - 29 x 1.9

HpEOC17.jpg


The Motor - Magic Pie II 48V - purchased from lighly used from Neptronix in the used section of this forum. No internal controller. Conveniently pre-laced to a 29er rim, upgraded phase wires and and shipped with a 7-speed freewheel. $177 shipped. Thanks Nep!

The Controller - 12fet Lyen - purchased directly from Lyen with a lot of other bits that I needed: throttle, 3-speed switch, torque arm, brake levers

Battery - this is the only item left to figure out. Was originally looking at a "high-discharge" BSMbattery.com li-ion but they don't seem to have the greatest reputation here, so I decided not to go with them. I'm likely going to go the LiPo route, since fun is the goal and then I can really dump some current into it. Looking at 2x HK 16Ahr 6S 10C but still doing research. I'll do a detailed post here once I get my batteries figured out. Thanks Nep for all the help!

The batteries and controller will be stored in a Revelate Tangle frame bag. I've alreayd received this, and while it's slightly too long to fit on the top tube, it fits really well on the down tube. Plus that will get my CG lower too. You can see that there's plenty of room for the 2 lipos, controller and the inevitable rats nest of wires... Plus there's a little port at the top for the wires to go in (probably for a hydration bladder). Really great quality bag.



q2SyKpq.jpg



Motor should get here next week, but I'll be in and out for a few weeks for vacation, so it may be a slow build. But I'll use this area to show progress, results and most importantly ask a bunch of questions!

Current Total: $827
Bike - $300
Tires and Fenders - $115
Motor + rim + freewheel - $177 shipped
Controller, torque arm and other bits - $235 shipped

Left to buy:
Cycle Analyst V3 - $150
Lipos, wiring and chargers - $400?

Projected total: $1377

That's where I'm at now, thanks to everyone here for being so helpful... The info can sometimes be hard to find, but most of it is out there if you do a little digging...
 
Wow the 16Ah are finally back in stock. It's been months... if you go this route, get em quick! I have a couple and like how simple these big multistar are to turn into a pack.

Ah thanks for the heads up. I went ahead and ordered two of them just in case they went out while I'm on vacation (says 10+ in stock in the US west warehouse).

They seem like a really good space, weight, cost and energy dense solution... now just to keep reading up on Lipos so that I feel comfortable using them...
 
Some of my current questions bouncing around in my head if anyone wants to offer insight:

-Currently have a 3x8 gear setup, and the new wheel will have a 7-speed freewheel. It seems that a number of people switch to a single chainring up front. I do hope to use this bike in pedal assist mode, and with steep hills in SF I may find myself needing the little ring? Any reason to keep the front triple or should it go?

-Anyone else have interference issues between the trigger shifters and the throttle? no matter how I rotate it I can't seem to get the index finger trigger to travel far enough to change the gear. Easiest solution is to just grind down the trigger until it shift but I'd like to avoid that if possible...

-Any concerns not having a suspension fork? I've got a nice heavy and solid steel frame, and largish 29" tires... seems like anything over 25-30mph may get bumpy?

Thanks in advance for any thoughts!
 
Out of curiosity, what kind of hills are you specifically looking at? and how much weight will you be hauling up? When your bike goes up a hill, it will need to go pretty fast compared to normal riding... so, you really don't need granny gears or anything like them. You might want to avoid the steeper hills to be honest. Like, instead of taking Dolores, cut over to Valencia :)

Suspension would be very nice, maybe even critical at high speed. So perhaps you will have to tone it down on SF's shittier streets... you can get probably get fatter tires if you need too or a suspension seatpost.

Security comes up a lot, there's a long thread you should find and look at for ideas. Everyone seems to have their own level of worry about security. Personally I don't go very far from my bike in SF because it has quick release wheels and relatively nice seat post/saddle that I don't want to lose. I did use one of these http://lockalarm.com/products/all/cable-lock-alarm-2-4m-8ft/ for a short time. Maybe it could help with your bag, hit me up on PM if you would like to try it out.

As far as disconnecting your bag, you could securely fasten the controller and take the lipos out. They only weigh 10 lbs, and there's one connector. I can't imagine disconnecting the controller every time.

Last thought, make sure those lipo bricks are well protected from dings and dents, especially the corners!
 
Out of curiosity, what kind of hills are you specifically looking at? and how much weight will you be hauling up?

Thanks for the input! I don't plan on seeking out hills, but if my new bike allows me to tackle some that I would normally avoid that would be nice. I'll lbhave to see how the setup reacts to steep hills at full throttle. I'm pretty light at ~155lb, but the bike is kinda heavy, maybe around 27lb before the conversion...

I'll see how the bikes feels rigid as I increase the power. If it gets too bumpy I suppose I'll have to find a cheap 1-1/8" 29er suspension fork. Fortunately for me they're slowly repaving the section of the mission that I live on... so it's nice smooth asphault :)

I think for security I'm going to replace as many bolts as possible with security torx bolts from McMaster, which I think will be harder to bypass than the standard security 5mm hex cap screws. I'm thinking of making a singlular internal volume that contains the two lipos and controller that easily slides in and out of my frame bag, and consolidate as many cables into a single connectors if possible. Then when I have to lock my bike up I just unplug that brick and toss it in my ruck (fingers crossed the lipos don't burst into flames on the train or at work)...
 
I was pretty unimpressed with the Chinese throttles that came with my controller and I wanted to make it a little more comforable and clean visually. I pulled off the grips on the original throttles and slid on a grip that I cut to make my own throttle. Really happy the the way it turned out, it's a nice soft rubber for the bumpy roads and gives me a decent grip on the throttle.

Here's the throttle before the mod:

AKZErCu.jpg




and after my modified grip.



and the final cockpit sans CAV3...



Throttle, 1-2-3 PAS speed switch, and front mechanical disc brake lever, which should trigger rear regen braking from the hob motor, may upgrade to BB7s in the future, front definitely, rear maybe. Here's a pic of the bike w/ all the wires going into the frame bag.

RMiC0NL.jpg


It's coming together. I'll put together a post with the Lipos and accessories that I ordered for this build soon.
 
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