My Ebike with OLDSCHOOL aesthetics Buildthread

[carl2.0]

Thanks for the heads up, and Ill look into the Wattmeter

 

[carl2.0]

Jus scoped through BMSbattery website.. these guys have some good prices... Anyone have any purchase experience with them ???

 

[Hillhater]

Jus scoped through BMSbattery website.. these guys have some good prices... Anyone have any purchase experience with them ???

here is one .
http://endless-sphere.com/forums/viewtopic.php?f=4&t=33405

do a search on the Battery tech section , you will find quite a few reports.

 

[carl2.0]

REally starting to feel the Lipo vybe,
been reading the noob threads, checking out thye recommended parts list n this is what I think I might go with:

-4 4s 5Ah batteries ( read a review on the kit Im looking to buy and the guy said the Capacitors are rated at 63V so 59V should be ok)
... A bit concerned with over charge here tho if each cell goes to 4V ill be goin in at 67.2 :S

http://www.hobbyking.com/hobbyking/..._5000mAh_4S_20C_Lipo_Pack_USA_Warehouse_.html

-One 4x6s charger ( Im hoping this is a reliable one ... I saw ypedal using it for some of his builds on youtube)

http://www.hobbyking.com/hobbyking/...x6S_Lithium_Polymer_Battery_Pack_Charger.html

or maybe the cheaper hobbyking ?

http://www.hobbyking.com/hobbyking/...CO_4_x_6S_Lithium_Polymer_Multi_Charger_.html

- One Ac power source

http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idproduct=6477
this is only 75Wp tho so I dunno if its enough :S
- 4 Voltage Monitors

http://www.hobbyking.com/hobbyking/store/__7704__Turnigy_Cell_Diagnostics_meter_2S_6S_.html

that should run me around $305 US not bad for a modular pack
Am I forgetting anything ?

 

[Hillhater]

A few points..
Those chargers have a poor reliability rep ! .. keep looking.
Consider the BMSBattery higher power "bulk" charger set to full pack voltage, and a low powered balance charger for occasional use.
Also you will soon feel the need for a 200+ W charger.
4v per cell is not overcharged, infact it is not even full charge !. 4.15v is considered a "desirable" charged cell voltage.
Why are you suddenly aiming for a higher system voltage (60+v) and low battery capacity ( 5 Ahr)?? That wont get you very far down the road. And will likely fry your controller too.
I would suggest you stick with 48-50v and 10Ahr to start , using 2 6 cell 5Ahr packs in parallel ( for 10Ahr) , then series another 2 packs to give you the 48v. (50v full charged.)

 

[carl2.0]

Hey guys

Parts take forEVER to get to Barbados sometimes n customs is slow around christmas so, the project is creeping along ...But I do have some pics

This is the donor... in pretty bad shape honestly... was trying a thing on it from a previous project. This was my botched effort to carry the seat back 2 yrs ago :S



Personally I think its too flimsy a frame to add 50lbs on so I have my eyes open for a nice sturdy cruiser frame (locally sourced)... prolly used. That dropout connection looks like disaster waiting to happen



This is Half of the pack 48v 7ah the full pack should be 48v at 14ah... This is my "starter pack " guys so pls dont crucify me, Im lookin to go with 16ah headways next yr. Im a negligent person... I should stay away from Lipo




Oh n here are some new renders. Since I dont get to play with the real thing as yet, messing around with the 3D model coaxes the depression
This is the new battery mounting position with the 7AH batteries.



I had to change the angle of the seat post... the old angle was too low would make for a nasty pedallin experience

View attachment 4

 

[carl2.0]

Making some progress these days, Ive got most of the fabrication done, still only purchased half the battery pack tho .









I placed the battery in just for the pic, nothing really securing it in... it fell out shortly after :S







Got all of my pack now, one seems a bit gasy tho..the new one

 

[carl2.0]

Hi all

I can definately say i havemnt been keepin this build thread up to date so hear it goes

The Old Seat Design

Time to tear down for the upgrade

The New Seat

Time to start working on the Body panels. Used insulation foam panels.. this particular type had some type of glassfiber paper on the sides BAD idea to use but it was free

Slowly Making Progress

2 weeks later One side down one to go

View attachment 5

4 weeks later

Time for some painting to Prep for fibre glass work. I was advised to paint them in automotive express primer (REALY pricy) I fill any spaces with wood filler which relatively cheap



Almost there !!!! These are not the finished panels as yet just the painted foam.. I put them on the bike to do a fit analysis, so far so good. Its a very basic affixing method (too basic I fear) 3 bolts 1 through the seat tube one at the < space connected to the head tube and one low down

I think I manage to get pretty close to the rendered image especially for a bodywork noob

Think Im going to have to mod the seat some more . Next post Ill have some instrumentation to show. Im installing electrical aswell as thermal monitoring
Hope you like it so far

 

[Samd]

Hey I am really enjoying this.
I am building a similar unit atm. Black and tan looks great.

Triple clamp forks are hard to find here in australia, unless you pay hundreds of dollars for brand name downhill forks...
Did you buy those over the web?

 

[Chalo]

Hey I am really enjoying this.
I am building a similar unit atm. Black and tan looks great.

Triple clamp forks are hard to find here in australia, unless you pay hundreds of dollars for brand name downhill forks...
Did you buy those over the web?

I'm guessing he bought them online, because he's in Barbados.

Those forks are rigid, made for chopper bicycles. Where I live, they are the preferred forks for pedicab trikes.

http://www.choppersus.com/store/product/833/Fork-Cruiser-Short-1-1-8"-CP/
http://www.bicycledesigner.com/bike-parts/bicycle-forks/28-chopper-fork-1.html

Chalo

 

[Samd]

Hey carl, we have a company here in aussie that rebirths motorbikes as cafe racers. You may enjoy some ideas.

http://au.deuscustoms.com/motorcycles/

 

[Samd]

Hey thanks Chalo.
It gives me an idea, I wonder if I couldnt retain my current forks on my build and make up some fake extenders between fork and headstem height. Then repaint the lot....

 

[carl2.0]

Yup Chalo is right i did buy it online, I actually got mine from http://www.jnmotorsbikes.com/


Samd, this bike has been my desktop back ground for weeks now, but I didnt know who built it I just took it from a blog

http://au.deuscustoms.com/wp-content/uploads/2012/05/Ryans-Triumph.jpg

Thanks alot for the link, lots of good stuff

 

[Samd]

Well you might enjoy this too:
http://www.voltagecycles.com/gallery/

 

[Staunch Trooper]

Nice one, like your idea of trying to keep some old school cool.

 

[Lessss]

Parts take forEVER to get to Barbados

You BASTARD! (gets to live in Barbados)

 

[carl2.0]

LOL for doing projects like this living in Barbados is NOT a plus... I have to order 80% of my parts online.. it takes at the very least 2 weeks for things to get here, importation taxes are high AND no one knows how to fix these things if they get broken..

Besides that the sea n sun is pretty good

 

[carl2.0]

Well you might enjoy this too:
http://www.voltagecycles.com/gallery/

Really liking his vintage approach!! nice choice of seat too,

thanks for the link

 

[Samd]

How's the build going?

 

[carl2.0]

Hi guys,

Sorry I havent posted anything on the build in a while.. I tend to update the photos elsewhere more often (terrible I know). Soo I got the body work done in fibre glass nice n solid 4 layers done by a professional (Yay no glass in my lungs !!) Also I installed my impression of a clip on handle bar arrangement using two 31.8mm stems locked onto the chopper fork tube. Limme know what you think..

Heres the bike with the raw fibre glass panels, they fit fairly decent, I was very pleased (especially since the fibreglass man was so intrigued with my project he did them for free !!!)

And Drum rolll please................................................. I got the body work completed on the fibreglass panels Its so shiny !!!! i was very content with the work done by this craftsmanit wasnt free by I was more than pleased to give him my money.

There is still a very visible space between the panels I'm thinking about covering that up with a magnetic strip glued on both panels. the magnets should make a water tight seal and I wouldnt need any tools to disconnect at the point of contact. I was thinking about a rubber gasket but I could think of any that would work for this application... maybe I dont know where to look :S Any thoughts ?

And Heres the Look of the finished bodywork on the bike. I got i nice sunny day for this shot too Please share your thoughts on the project thus far

 

[carl2.0]

Ok,

So i had the crazy idea of using some light motorcyle suspension fork in my chopper triple clamp to get some cool looking suspension on the cheap.. or so i thought. From my experience meshing motorcycle parts on a bike is definately not cheap. I had to change the hub for the front wheel to one that would correspond with the motorcycle fork... This hub had to be shaven down n other stuff to fit. Motorcycle spokes had to be used instead of my normal spoke And i decided to use the Motorcycle disc break for a hydraulic configuration. Lets See How it all went

Here's Piwi at the Motorcycle shop fitted withe the new forks shims were needed ofcourse

After 2 weeks of waiting I finally got my respoked rim with the motorcycle hub and disc I like !!

PIWI with Front Suspension and Hydrolic Front disc brakes.. Also installed my vintage springer seat

Its coming along.. slowly but surely

 

[contador]

Looks great man, nice built and very close to the renders you made...congrats

 

[carl2.0]

Thanks guy,

It took most of the time getting it to 'look right' At this time the challenge is compatibility... My experiences definitely indicates now that mixing motorcycle parts n bicycle parts is an expensive affair. Change of one pair ends up in the change of several... or some very fancy fabrication :S

On the Up side I'm very pleased with how its comin along... Im more getting a Vintage Scrambler feel from the bike than Cafe racer with the motorcycle front end, what do u think ?

 

[Chalo]

Your bodywork reminds me of the high capacity tank on the BMW R80GS Paris Dakar. But it doesn't really remind me of any other motorcycles.

You could easily reinvent the style of your bike as a desert racer if you wanted to go that way. You wouldn't even need long suspension to evoke the image. Just high mount fenders and perhaps a mini fairing would do it.

 

[agniusm]

Hi. I think you dont have proper workshop and the job you have done is amazing. I was always fascinated on people doing something special without too much tools and having little parts to play with.
It looks very good, the only thing i like it better as per you design, big front wheel with noticeably smaller rear. Does make that final look.
Congrats