New build. Full carbon 29er weight weenie Super Commuter.

[Kepler]

Preparing for winter commuting. Added a new seat bag that neatly holds 3 x 6S 3.3ah packs for around 200Whr usabe. Suits my 20kM commute nicely. Weight of the pack including the bag is 1.8kg





Also added the front bag which holds my charger, puncture kit etc. Also is used to mount my 2000 lumens lights. Rear light is 1W so no excuse not to be seen.

 

[pendragon8000]

. Rear light is 1W so no excuse not to be seen.

1 watt.. that's not that bright. I consider you an "ebike Jedi" but 1watt is bugger all IMO
I run 3watt x5
Everything else looks amazing

 

[Kepler]

Wow 15W rear lights, now that is ninja. . Cars and bikes behind must love you i get complaints on my measly 1W being annoyingly bright :lol:

 

[pendragon8000]

Yeah fair enough. I am a bit over cautious I admit.

 

[t3sla]

hooray, non HK rc lipo!

The last time we met I talked about how your build really inspired me to change direction on mine (spearheaded by a Bafang CST and desire to use a quality cogset)
So a well balanced (lighter weight) and stealthy clean look was the main goals.

I have the same seat-post bag and it accommodates 2x6s 8ah nano-techs (very snug), but I wanted to play with the an idea for super clean top bar mounted bags (this isn't how I want the bike to be setup, but rather a test of design)

I do believe that most if not all bike bags aren't capable of the battery loads we have in them, so I set to use the bag as purely aesthetic trickery (it even has a Giant logo) :lol:

 

[rp3]

t3sla, how do you not hit that bag when you pedal?

John, nice clean work like usual. :wink:

...

 

[t3sla]

t3sla, how do you not hit that bag when you pedal?...

Just has enough clearance, it's 20S8ah pack that's made for track racing so not much pedal movement needed.

The goal to see if I could make a clean 'invisible' mount that took the bags load with minimal wear/play.
I really liked Keps approach of 'it looks just like a bag', I believe I can do something similar with the seat-post bag so that it lasts longer.

 

[Samd]

Looking awesome Kep. Have the harmonics of the Bafang/carbon frame settled down a little with the new hub's gears wearing in a bit?

It'd be interesting to swap out for a full sine controller and see if a smoother phase signal removes some ringing maybe?

 

[Kepler]

I do believe that most if not all bike bags aren't capable of the battery loads we have in them, so I set to use the bag as purely aesthetic trickery (it even has a Giant logo) :lol:

[/attachment]

I think the stylish duct tape around my last seat post bag would confirm that :lol:

This latest bag isn't too stressed with the amount of LiPo I have shoved in it so hopefully it will be OK.

 

[Kepler]

Looking awesome Kep. Have the harmonics of the Bafang/carbon frame settled down a little with the new hub's gears wearing in a bit?

It'd be interesting to swap out for a full sine controller and see if a smoother phase signal removes some ringing maybe?

I ended up changing out the motor with the second motor being much quieter. Still not silent though. Would love to try one of those sine wave controllers too.

In fact a sine wave controller with a friction drive would be very interesting in relation to noise level. I could then re fit my high spec rear wheel which I originally had on the bike. The crappy hub motor gear cluster lets this bike down a bit. I would love to go back to a nice close ratio high spec 10 speed cluster as l do lots of gear changing on this bike.

 

[-dg]

This latest bag isn't too stressed with the amount of LiPo I have shoved in it so hopefully it will be OK.

What bag is that anyway? I think I need one.

 

[Kepler]

http://www.chainreactioncycles.com/Models.aspx?ModelID=73525

Bargain price for what looks to be a very nice bag. I got the large one which is 1500ml in volume.

 

[Samd]

If you go around quoting bags in litres I'll just sit at my desk converting it to pints and dreaming of filling it with delicious beer Kepler. 8)

 

[Kepler]

Needing a bit more range this week so I have gone with 18S 5ah packs in the front bag only. The extra capacity lets me run the bike a bit quicker too with 850W on tap to hold good speed up most hills. Good thing about the batteries at the front of the bike is that it makes the bike a little more balanced.

Here is a comparison of the look. Still under the radar I think

 

[pacamu]

i love this project.
well done

 

[Whiplash]

When I get my big build done, I'd really like to do one like this for the work commute but use a cheap eBay carbon frame as I don't have the coin to do a classy build like this! Well done!

 

[Kepler]

moderator edit: the motor shown is the Bafang SWXH

Thought it was about time I fixed the seized free wheel in my geared hub today. Ended up being quite a job. Not so much replacing the planet gear assembly, but just getting the motor apart.

This geared hub has a screw on cover that has 3 recessed holes used for disassembly using a specialised tool. I tried getting it apart with a C spanner and strap wrench to hold the motor, but not a chance. Decided best bet was to get serious and make a proper tool for the job. Here is what i came up with.


The Aluminium block attaches to the disc brake mount so you can hold the motor securely.



A big shifting spanner or pipe is then used for plenty of leverage





Mounted up in the vice ready to get serious.





And finally apart after leaning on the spanner like I was trying to undo wheel nuts on a truck.



Replace the planet gear assembly and packed it with new grease (much more then original). Took it for test ride. Perfect. Nice and quite and the bike rolls again. Well worth the days effort.

 

[dbaker]

Great tools to have! You could add them to your products for sale

 

[t3sla]

The tools have more engineering and metal than the motor... Hahaha

The bag in the front looks more stealthy, can't explain why.
Maybe the mind just glances over it more, is your controller still under the BB?
If so how are you running the wires, figured the frame is white so the AC flat home cable might stealth it up.

 

[Kepler]

It isn't going to break that's for sure. :lol:

I am glad the front bag doesn't kill the stealth look. It is a lot more practical then the rear bag that's for sure.

Battery cables just run under the top tube and sits between the two derailier cables. They then track down the seat tube behind the carbon fibre cover. Still hard to spot.

The flat white cable should work well. I might go to that a bit later. Just keeping my options open with the front and rear bag at the moment.

 

[spinningmagnets]

Hmmm...look what I found: http://www.electricbike.com/kepler-super-commuter/

Just kidding, I'm a spell-checker and occasional writer for electricbike.com, Eric wrote this one...

 

[Samd]

Nice to read this summary over my morning coffee break!

I wish they'd put the author's name at the top of their articles though - never sure who is writing what!

 

[full-throttle]

Very nice writeup.

This photo however is crap

Feel free to use one of mine

 

[Kepler]

Thanks for that. I will get it changed immediately Sir.


Edit: Done.

 

[Marc S.]

Minor motor issue has crept in. Running a fair bit of 750W through the motor and 70V. The motor electrically is doing really well and doesn't get too warm. Also the gears hare coping fine with this level of power and as still quiet.

However, the sprag clutch or one way clutch as locked up so it no longer free wheels. Surprisingly the wheel still spins down quite freely; certainly better then the big DD hub motors I have used.

Still, something I need to fix so it looks like a job for today will be to manufacture a tool to open up one of these motors. Should be a good exercise just to inspect the windings and gears after the first 500km of operation

Hi Kepler!

Very nice build!

I run the Bafang SWXH (and Bafang BPM II) currently with 13s to 15s LiPo battery and 35A controller in my ICE Sprint recumbent trike and had clutch problems with both motors as well.

Since I filled 50ml ATF with a big syringe through the disk brake screw holes of the SWXH the clutch problems are gone. On top of that he motor is quieter now and I think freewheels a tad better. http://endless-sphere.com/forums/viewtopic.php?f=2&t=37972&start=375#p731095

I think the sprang clutch of the Bafang SWXH doesn't even get enough lubrication with the stock grease filling at its rated 250W for a longer period of time. My SWXH clutch started acting-up infrequently after 1000km or so when still run off a 10s battery and 15A controller.

No, running in an ATF oil bath, the more or less frequent sprang clutch lock-up is a problem of the past. Since the SWXH is better cooled as well I'm much more confident to use my ICE Sprint as my daily commuter with 14s battery at up to 45km/h WOT. It gets quite warm, though.