DogDipstick
100 kW
Hi, Jp here.
Been lurking and posting here or there, but never posted this build yet here. I like to test cells,build batteries and bikes, and get friends involved in this fledgling hobby.
Take a look at my pics, let me know what you think.
Bike:

North Face Kichatana, 7005Al DW link Ironhorse HollowpointXC, re-badge. A very good bike in 2004 with geometry that rivals modern bikes. Retailed with XT all around for about 1200$ until Dicks Sporting goods went bust. Bought busted frame only for 8$, proceeded to weld and braze back into riding form.
Shimano everything. Crank, quad pot hydro MT520. KMC chain. Shimano 14-32 freewheel, Acera derailleurs, Deore trigger shifters..... and Hayes 8 inch and a Hayes 160mm in the rear. VP pedals. RS Domain fork, Bontrager bar and topclamp. Pro Taper grips and donuts. Coils and oil only. I dont believe in airshocks for bikes. Proven to waste efficiency.
24.25" Dia wheels. Sur Ron hub on the front 110x20 36H, rims. 19" with a Duro " Vintage Mc" 2.5" x 19" DOT rated tire. DOT rated rim. 12 G spokes in Sapim stainless and brass nips. Says DOT on the rim and tire. 9.99 lbs front (measured), 24 lbs rear(guess)..... Tire itself is 4.2 lbs, lightest I could find. Shinko weighs twice as much in that size.
Install:
Qs 205 V1 35h 8.5KV
GRIN Ca3-DP with all the knobs and buttons, shunt, ect.
GRIN TCDM chain tension metering BB Tq. sensor.
Kelly KEB 72330, 50/100A controller. 3.3Kw contin. 90v max.
Domino Throttle, from a Zero.
15.5Ah Chevrolet Volt NMC lipo in a 20s, 1p configuration. Quite powerful, if you ask me. 82.5V fully charged with 1278 Wh. IR is 1.2-1.4mOh/cell. Ca3 registers anywhere from .040, to .070, for the IR on a cold day. I would not fear 250A plus contin, if I had the controller to push it. They are certainly proven 1000w/cell in my opinion. Reliable and cost effective.
DC/DC 9v converter. Precharge circuitry. 7w headlight, tail light is one of those accelerometer tailights. The main key is a Hella 2843.
3 riding modes. ECO ( 750w, 25mph), NORM(40A,and 33mph), and UNLIM (full 100A,).
I am sure there is a bunch of stuff I'm leaving out.
The whole bike is 85 lbs, about, give or take. Weighed on a bathroom scale.
Some people have seen issues in my build, such as " lights not bright enough" or " too soft" or " pack gonna hit the tire"... " hubs heavy".. Well Im proud as can be about this bike, dont think it is to soft, have not bottomed out the forks, and the DWLink is like pedaling up a cloud, IMO. I can climb stairs in parks with it and can sling donuts in mud probably 40 feet. Lightest hub/tire/wheel combo I could find. I'll happily hit whoopdedoos at 35mph. It trucks through playing fields unlike any MC I ever had.. silent, smooth and fast.
I built and bent the case myself. Wired everything with high current 8Ga hook up wire. Copper nuts and bolts in all power transmission fasteners.
Final cost? ~1300$ to build, signed sealed and delivered. Minus labor....
The CA3 shows 6500+ watts on acceleration in UNLIM. Top speed is about 40mph loeaded on flat ground. Unloaded I pull 3A @ 49mph.
I might paint it in white pearle BC/CC.. and hydrodip the box. IDK. We'll see.
Some things dont make sense for me.
First is the shunt readings and the Kelly. Kell says it is a 50/100A controller of 3.3Kw. However, peaks on the CA2 show 65-6700W and 95.6A maximum battery draw. How is this possible if Kelly rates the controller in phase amps? How many phase amps do I pull, on this bike? I thought it should have been 100A phase, and the battery would be no more that 70% of this.. but I regularly hit 90+ amps on the CA3. Every ride on UNLIM. The shunt does work, as does the dial AUX I use to fine tune the amperage delivery. I set it at 40A, shunt shows 40A max. Ect.? Speed limiting and amp limiting work flawlessly on the PAS setting I have laid out in the first two (mild) modes. I have PAS disabled on the UNLIM setting.
So why is my "3.3Kw" Kelly showing 90+ amps and 6700W? When entered into the calculator on GRIN the map looks right.. top speed, throttle, Ft/second/second, all the normal numbers. Says I put down 4.5Kw and pull 6500battery watts with the "Leaf 35H " motor chosen in my Kv.. ( the clone that which the QS is)....
Top speed with me on it ( 260lbs bike/rider) loaded is 2200W~ @ 38-40mph. Right on mark according to the calculator.
First time I rode it on 80v ( 18s charged full) it nearly tore both my MCL and ACL on a violent wheelie, in motion from 5-8mph. I didnt know it would react like that, I mean I figured I would be able to handle this "1000w" hub. Threw me off like a pissed off pony. Went sliding down the road 25 feet to a road rashed stop as I landed, sliding on my MCL and an ankle. Landed hard on my inside knee, and outside ankle at the same time. .... Snipped the laces right off my soldier boots. Lol. That hurt, still does. No permanent damage, fortunately. I've tossed a few MC in my time, and a few have tossed me.
Lets let the pictures speak for themselves. I'll add more as the day moves on and my internet catches up.
Build:
View attachment 27

View attachment 25
View attachment 24


View attachment 21


View attachment 19




View attachment 11
View attachment 14


View attachment 8

View attachment 6

Torn up knee time: This happened with a backpack battery. Prompted me to strap the battery under the tubes. Front end still comes up easil, but not in a turn or unexpectedly. Honestly it is almost undrivable on 100A whe you flick it around a turn and want to accelerate... Tq tops out the fork, instantly with throttle, then you are holding the speed down to hold the front down... anywhere before 25mph...
I want to tune the CA3 throttle.. which is better? 99v/sec or 5V/sec? Idk. Response has been "scary" to "Im not trying it anymore..." to " now its a slug"..... I want to use the no load ramp but i dont even know the best setting for the normal throttle ramp.

This derauilur still works fine, ironically.
View attachment 28
FINISHED (for now) PRODUCT: So far I've gone about 420Mi, no problems and everythigs good after working out a few bugs and upgrading to 3.14.

Chillin next to the ol' ZedX9r in the foyer.

Thankyou everbody for helping me, I think Im done uploading for now.
15-40 Miles or MPH, you choose. 1278 Wh 80-100Wh/mi peak on CA3... 30-40Wh/mi min.
Been lurking and posting here or there, but never posted this build yet here. I like to test cells,build batteries and bikes, and get friends involved in this fledgling hobby.
Take a look at my pics, let me know what you think.
Bike:

North Face Kichatana, 7005Al DW link Ironhorse HollowpointXC, re-badge. A very good bike in 2004 with geometry that rivals modern bikes. Retailed with XT all around for about 1200$ until Dicks Sporting goods went bust. Bought busted frame only for 8$, proceeded to weld and braze back into riding form.
Shimano everything. Crank, quad pot hydro MT520. KMC chain. Shimano 14-32 freewheel, Acera derailleurs, Deore trigger shifters..... and Hayes 8 inch and a Hayes 160mm in the rear. VP pedals. RS Domain fork, Bontrager bar and topclamp. Pro Taper grips and donuts. Coils and oil only. I dont believe in airshocks for bikes. Proven to waste efficiency.
24.25" Dia wheels. Sur Ron hub on the front 110x20 36H, rims. 19" with a Duro " Vintage Mc" 2.5" x 19" DOT rated tire. DOT rated rim. 12 G spokes in Sapim stainless and brass nips. Says DOT on the rim and tire. 9.99 lbs front (measured), 24 lbs rear(guess)..... Tire itself is 4.2 lbs, lightest I could find. Shinko weighs twice as much in that size.
Install:
Qs 205 V1 35h 8.5KV
GRIN Ca3-DP with all the knobs and buttons, shunt, ect.
GRIN TCDM chain tension metering BB Tq. sensor.
Kelly KEB 72330, 50/100A controller. 3.3Kw contin. 90v max.
Domino Throttle, from a Zero.
15.5Ah Chevrolet Volt NMC lipo in a 20s, 1p configuration. Quite powerful, if you ask me. 82.5V fully charged with 1278 Wh. IR is 1.2-1.4mOh/cell. Ca3 registers anywhere from .040, to .070, for the IR on a cold day. I would not fear 250A plus contin, if I had the controller to push it. They are certainly proven 1000w/cell in my opinion. Reliable and cost effective.
DC/DC 9v converter. Precharge circuitry. 7w headlight, tail light is one of those accelerometer tailights. The main key is a Hella 2843.
3 riding modes. ECO ( 750w, 25mph), NORM(40A,and 33mph), and UNLIM (full 100A,).
I am sure there is a bunch of stuff I'm leaving out.
The whole bike is 85 lbs, about, give or take. Weighed on a bathroom scale.
Some people have seen issues in my build, such as " lights not bright enough" or " too soft" or " pack gonna hit the tire"... " hubs heavy".. Well Im proud as can be about this bike, dont think it is to soft, have not bottomed out the forks, and the DWLink is like pedaling up a cloud, IMO. I can climb stairs in parks with it and can sling donuts in mud probably 40 feet. Lightest hub/tire/wheel combo I could find. I'll happily hit whoopdedoos at 35mph. It trucks through playing fields unlike any MC I ever had.. silent, smooth and fast.
I built and bent the case myself. Wired everything with high current 8Ga hook up wire. Copper nuts and bolts in all power transmission fasteners.
Final cost? ~1300$ to build, signed sealed and delivered. Minus labor....
The CA3 shows 6500+ watts on acceleration in UNLIM. Top speed is about 40mph loeaded on flat ground. Unloaded I pull 3A @ 49mph.
I might paint it in white pearle BC/CC.. and hydrodip the box. IDK. We'll see.
Some things dont make sense for me.
First is the shunt readings and the Kelly. Kell says it is a 50/100A controller of 3.3Kw. However, peaks on the CA2 show 65-6700W and 95.6A maximum battery draw. How is this possible if Kelly rates the controller in phase amps? How many phase amps do I pull, on this bike? I thought it should have been 100A phase, and the battery would be no more that 70% of this.. but I regularly hit 90+ amps on the CA3. Every ride on UNLIM. The shunt does work, as does the dial AUX I use to fine tune the amperage delivery. I set it at 40A, shunt shows 40A max. Ect.? Speed limiting and amp limiting work flawlessly on the PAS setting I have laid out in the first two (mild) modes. I have PAS disabled on the UNLIM setting.
So why is my "3.3Kw" Kelly showing 90+ amps and 6700W? When entered into the calculator on GRIN the map looks right.. top speed, throttle, Ft/second/second, all the normal numbers. Says I put down 4.5Kw and pull 6500battery watts with the "Leaf 35H " motor chosen in my Kv.. ( the clone that which the QS is)....
Top speed with me on it ( 260lbs bike/rider) loaded is 2200W~ @ 38-40mph. Right on mark according to the calculator.
First time I rode it on 80v ( 18s charged full) it nearly tore both my MCL and ACL on a violent wheelie, in motion from 5-8mph. I didnt know it would react like that, I mean I figured I would be able to handle this "1000w" hub. Threw me off like a pissed off pony. Went sliding down the road 25 feet to a road rashed stop as I landed, sliding on my MCL and an ankle. Landed hard on my inside knee, and outside ankle at the same time. .... Snipped the laces right off my soldier boots. Lol. That hurt, still does. No permanent damage, fortunately. I've tossed a few MC in my time, and a few have tossed me.
Lets let the pictures speak for themselves. I'll add more as the day moves on and my internet catches up.
Build:
View attachment 27

View attachment 25
View attachment 24


View attachment 21


View attachment 19




View attachment 11
View attachment 14


View attachment 8

View attachment 6

Torn up knee time: This happened with a backpack battery. Prompted me to strap the battery under the tubes. Front end still comes up easil, but not in a turn or unexpectedly. Honestly it is almost undrivable on 100A whe you flick it around a turn and want to accelerate... Tq tops out the fork, instantly with throttle, then you are holding the speed down to hold the front down... anywhere before 25mph...
I want to tune the CA3 throttle.. which is better? 99v/sec or 5V/sec? Idk. Response has been "scary" to "Im not trying it anymore..." to " now its a slug"..... I want to use the no load ramp but i dont even know the best setting for the normal throttle ramp.

This derauilur still works fine, ironically.
View attachment 28
FINISHED (for now) PRODUCT: So far I've gone about 420Mi, no problems and everythigs good after working out a few bugs and upgrading to 3.14.


Chillin next to the ol' ZedX9r in the foyer.

Thankyou everbody for helping me, I think Im done uploading for now.
15-40 Miles or MPH, you choose. 1278 Wh 80-100Wh/mi peak on CA3... 30-40Wh/mi min.