My Stink-E

[etard]

Awesome ride Garrick! Velcro is an amazing product if you think about it, yours should do well until you want to upgrade anyway. Can you give some details on the performance (specifically watts and watt hour usage) you have with this setup and how the bike performs on trails? Also, how much does it weigh?

Outstanding, well I'm off to search up used Stinkys now dammit!

 

[hotrod]

nice clean build mate

 

[SoMoney]

Yup... The sexiest e-stinky...... errrr; "STINK-E" on endless-sphere PERIOD.....

You really need to detail those side panels bro (as in give us the step by step)! :?

PS. Put a Gopro on that rig and show us what you got

 

[Garrick_s]

I here you.....

I'm gonna borrow my brothers Helmet Cam this weekend and I'll try and get out for a whomp and get some footage.

As far as the side panels go.....
I've been talking to my patent attorney and he suggests that I shut my mouth on those until the Patent is in place...Just joking
I post some pics soon.

 

[Drunkskunk]

One more Stinky on the boards. We need to rename this Endless-Stink

Thats a bad ass build.

 

[67spyder]

This is a wonderfull bike! I wish I could have found a Stinky myself but here in the flat prairies I felt I was lucky to find my used Scrap (Scrap-E) Seriously, looking forward to a video post both to see your bike in action but also to see some not -30 weather :wink:

 

[Garrick_s]

Can you give some details on the performance (specifically watts and watt hour usage) you have with this setup and how the bike performs on trails? :

First off - I am clue-less when it comes to electrical info and what everything is doing.
This is all new to me. I'm use to dumping in some 91 octane gas and grabbing a handful of throttle.
BUT - I am here and building my own electric bike because I see this as the future - so I want to learn.

THe Motor
Right now the motor was sold to me, rated as 1800w.
I'm running a 48v - 10Ah battery set-up. LiPo batteries
When I'm climbing hills or pushing full throttle hard, I've seen my Cycle Analyst read 1900+ watts pumping out.

As far as watt hour usage - I don't know
I need to read up on the CA manual to learn everything it's telling me.
Right now it's just a fuel gauge for me. I watch the AmpHours used and when I hit 8Ah burned up, I'm done.

Performance on the trails..............
total weight right now, she sits at 63lbs. I got the Batteries as low as I can get them within the frame.
But with everything nice and snug, she handles like a dream.
I'm just waiting for my rear rim to blow-up or a magnet in the hub to pop off.
I can tell these motors were not made for hammering in rocks and such.
I will ride this thing until it goes.
I may see about Hyenas "Hadron mark IV" once this BMC blows....

Fortunately, the Bike itself will remain a great platform for future builds too.

 

[briogio]

Gotta admit you've totally inspired me! After seeing the Australian "Stealth" bikes I decided I really wanted a full-suspension e-bike, but they're way too far away to import, plus I'm a cheap-ass , I think the Stinky is the best and most plentiful mtb to use, plus I really like the way you've integrated everything into your frame space and then covered it, nice and tidy. Do you have any idea how much it's cost you to build? not including the bike itself? and are you doing any jumping or intense banging around? Interesting to hear you say the hub motor may not take the banging too well, please let us know if, and what, goes wrong. Thanks for doing my prototyping! and it's a very cool e-bike you've built :wink:

 

[Garrick_s]

Thanks Briogio,

The off-roading I'm doing with this rear hub, is not very easy on it.
This is mainly when climbing on dirt single tracks.
Alot of rocks and bumps that tend to put a heavy load on the planetary gears.
Yes I jump and hammer pretty hard.

When coasting or going down hill, it's not so much a concern.
You also have to pay attention to throttle control when jumping off of curbs and such.

Cost: For the kit, it's around 2K (hub motor assm laced with rim/ controller/ throttle/ batteries/ chargers).

Good luck

 

[kfong]

I'm glad you are having fun on that Stinky, I'm just as hard on my build when I ride and have yet to run into any issues with the motor. I'm running the V2T version. It sounds like yours is the same since you are running just a bit faster on 48volts. I went with 40volts since I wanted to be sure not to over power the motor but this gives me a 20-21mph speed, perfect for single track trail riding. It's the higher power setups that have been toasting the gears from the reports I've been reading, but I think you should be ok on 48volts. Too bad I wasn't able to find a used Stinky when I started the project, still happy with my Motobecane since I bought it new. I wasn't able to find any equivalent bike without having to buy a used one for that price. Still waiting on spring.

 

[Whiplash]

Hey great build and I am doing a similar setup with a much less expensive bike, but it has a similar layout. I am using R/C power for mine, but I LOVE the fairing idea! Where did you get the ABS sheet from? Is the Velcro that earthquake stuff that bites really hard or just the normal stuff?? Thanks! one of the best looking bikes I have seen!

 

[Mark_A_W]

Nice build, I like it. About time someone did another dually build.


But be careful on the motor. I have a MAC motor fitted with a BMC V3 freewheel and gears, and after 2000k of abuse on the street, the freewheel is playing up (gears are fine though).

 

[Garrick_s]

Where did you get the ABS sheet from? Is the Velcro that earthquake stuff that bites really hard or just the normal stuff?? Thanks!

I got the plastic sheet from a local plastics shop in town.
4 x 4 sheet of .125" thick ABS was about 30 bucks.
I also bought the Heating strip there.

The Velcro is just off-the-shelf Velcro Adhesive strip - 3/4 wide.
It's been working fine so far - it only hold the weight of the plastic panels, so it's plenty strong for that.

Thanks!

 

[Garrick_s]

I'm running the V2T version. It sounds like yours is the same since you are running just a bit faster on 48volts. I went with 40volts since I wanted to be sure not to over power the motor but this gives me a 20-21mph speed, perfect for single track trail riding. It's the higher power setups that have been toasting the gears from the reports I've been reading, but I think you should be ok on 48volts.

I blew the clutch plate bearings on the first motor.
Then I ruined the motor, trying to dis-assemble it.

I now am running a V2T new motor (Thanks Ilia) - still at 48v (fresh charged batteries read 58V on my CA though)
So far so good - I;m gonna keep it at 48V for now.
I hit the 30MPH mark on flat, paved surface. It runs at a 20-25 avg on dirt - plenty for the local trails here.
The more I ride this thing, the funner it gets :lol:

Thanks

 

[Beavinator]

Nice build! This is one of my favourites!

 

[Kris B Krunch]

Hi, sounds like you did a really nice build there, but only one picture seems to be showing up now. Any chance you can repost some of your pictures? As I have a Kona Stinky primo I'm considering to build in the future too and would like to see especially how you did your frame mounted battery pack and covers.
Thanks

 

[Garrick_s]

Thanks

It's been a while since posting all those old pics.
Since then, I have changed to a direct drive rear hub and bumped it to 87V.
Same bike but re-did the battery frame to add the third battery.

I also made a second one for my brother, but his was done in a Rocky Mountain frame.
same internal frame design within the bike frame.
I posted a link here a while back, to a video we did on them. it was a blast.

Biggest problem I have lately is the brakes!!
They just cant take the punishment :lol: .

Anyway, Ill dig up some pics and post them soon.
Thanks for the props.

 

[Garrick_s]

Heres a couple of pics.
These show the old BMC motor still and I upgraded the forks too.
I will take some snaps of the internals this week hopefully.

 

[Whiplash]

Still one of my faces, totally inspired my build!

 

[crusoe]

Can you repost those pics at the start of this thread. I'm about to buy a stinky and your build looks right down my alley and budget. Great work!

 

[Drunkskunk]

Can you repost those pics at the start of this thread. I'm about to buy a stinky and your build looks right down my alley and budget. Great work!

Damn, Yet another Stinkist! We are going to take over this forum one day. What year and color are you going to get?

 

[crusoe]

I'm thinking 08-10 and I don't really care about colour to be honest. As long as it's not hawt pink I'll be fine with it lol

 

[Garrick_s]

Here's a couple of pictures of the battery frame I designed.
It holds my 3 - 27V~10Ah batteries perfectly and securely with no movement during jumps etc.
Also protects them from potential impact in a crash.

Picked up the material from a local hardware store.
The "Battery frame" is mounted inside the bike frame via pipe clamps and existing bottle cage mount holes.
Works F-in awesome and allows for no modifying of actual bike frame.





Due to area restrictions, the batteries must stay in place after assembly.
which is fine - I leave the batteries in the frame during charging.
Some have expressed concern of the controller getting too hot in the location I have it.
But after side panels are in place, due to their shape and front opening, they actually force quite a bit of air
down inside and keeps it nice and cool.

I have to look for the old pictures of the side panel creations.
Hope this helps you guys.

Thanks - I'm gonna whomp this afternoon I think.

 

[crusoe]

That is a wicked design! I love the multi-levels - ingenious! What voltage are you running at with those three batteries? And is that aluminium (how did you bend it?) Any vids?

 

[Garrick_s]

Sorry no vids of construction.

When it's freshly charged, the CA reads 87.9V
when whacked open, I'm pumping 4000W+ but I don't hold it at that too long..........usually .

The battery framing is all aluminum.
backbone is 2"wide x 3/16"thick aluminum bar.
I just figured out where I want my bends and torched it up and bent it.
The side walls are 2" angle bar cut to length (one per side of each battery).
Those are attached to the backbone frame via JB weld and rivets.
Each cradle is lined with a fairly dense 1/8" thick foam to pad the battery.

I just use 2" wide gorilla tape to hold the batteries into it's respective cradle.
It really works great. Very strong and reliable....the batteries don't move.

Since the Batteries are secured to the main bike frame, the side panels hold no weight other than there own.
They are held onto the frame via Velcro.

This complete system has been tested against the ground at 35+ mph a couple of times
The Batteries have been safe and sound and the side panels are bullet proof.

I've made the same system for my Brother with the same results......excellent.

Good luck in your build and post your results!!