[NOOB] Starting the first eletric bike

[marcos7007]

Hi, this topic will be my english Training and my steps to my first e-bike. Feel free to give me more links to read or tips to improve my english.

I started reading a lot because my actual eletric bike starts to give signal of retirement and I decide it is the time to move on. So I will build a eletric bike for me.

Old bike:
http://www.baogl.com
Mine is the U-bike 5.0 nano. I will talk more about this bike, since this project will help me to fix this old one.

bibliography:

1) http://endless-sphere.com/forums/viewtopic.php?f=2&t=44325
Thank you very much for this. It helped me a lot.

2)
http://endless-sphere.com/forums/viewtopic.php?f=3&t=26488

3) http://endless-sphere.com/w/index.php/Main_Page

4) http://www.electricbike.com
This is a website that helped me a lot, and helped me to find the endless-sphere. Also, I dicided to go with Lipo Batteries
Bought 4 x ZIPPY Compact 5000mAh 7S 25C Lipo Pack so far.


Other urls I read and watched
http://www.electricbike.com/hub-motor-factory/ Very good information about the construction
http://www.electricbike.com/optibike-battery-pack/
http://www.electricbike.com/ebike-porn/ ( the pieces I will need and use in the next steps of my bike, after I do the basic stuff)
http://www.electricbike.com/9c/
http://www.electricbike.com/optibike-battery-pack/
http://www.electricbike.com/lifepo4-battery/


5) Ok, so I read a lot of stuff, and I still felling like I know nothing.
In this step, I decided buy the charger. I choose this one
hyperion 14S balancing charger

And TURNIGY 3~8S Voltage Detector http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=13276


6) Connectors/ CRIMPING tool
http://www.endless-sphere.com/forums/viewtopic.php?f=2&t=29462
The second response helped to choose bullet connectors
I bought the connectors, and I will arrange to connect here.

"5) Hobbyking states 300 cycles, but some forum members here have got up to 600+ cycles out of lipos. Treat them nice, don't discharge over a 2-4C rate ( easy to do with 30ah, lol ), don't charge over a 1C rate, don't overdischarge past 3.0v, and charge your batteries to 4.15-4.10v/cell rather than 4.2v/cell and they should live a long life."
I will follow this rule for my batteries.
more details in this link http://traxxas.com/forums/showthread.php?481961-FYI-Lipo-Capacity-vs.-Resting-Voltage&s=00f91b45f0661b25b01a436d2e67fac2

I have found this climp tool for bullet,but It is too expensive
http://www.triumph650.com/servlet/the-1362/CS-dsh-0394--LUCAS-BULLET/Detail


7) Bike
http://endless-sphere.com/forums/viewtopic.php?f=3&t=29373
I did not choose the bike yet, but I hope to be something like this link
I hope will be full suspension.
I already booked my trip to USA and I will bring the bike from there.


8) Cables
http://endless-sphere.com/forums/viewtopic.php?f=31&t=45298
http://www.youtube.com/watch?v=O9WL05jYa2A
A lot to read. I decide do build my cables.
I can buy the cable here at brazil. I will buy the connectors together with the next batch of batteries I will buy.


9) Motor
Like this article says. http://www.electricbike.com/cheap-electric-bike/
I inteend to use the controller of this motor
48 volts 1000watts
http://www.conhismotor.com/
Yet, I dunno if the original controler can handle the voltage.
I will try, since my range will be 14s ( about 58volts)

10)
Parallel, serie cables.
http://www.rchelicopterfun.com/parallel-lipo-charging.html
I will need to parallel my cables and some in serie. both for the energy cables (10AWG) and for the JST-XH connector.
Since I want to charge all my four batteries as one.

http://www.revolectrix.com/MPA_XH.htm



Shoplist so far.
4 x 7s 5AH battery ( done, waiting arrival)
10 x pair bullet conector 5.5mm ( Polymax 5.5mm Gold Connectors 10 pairs (20pc) waiting arrival)
? meters of 10 awg cable (waiting)
1x hyperion 14S balancing charger ( first one was lost, bought a second, waiting for arrival)
4xTURNIGY 3~8S Voltage Detector ( done, waiting arrival)
1x 48v 1000w conhismotor ( done)
? bike ( After I have something working, I will start in some old bike to test)
1 x Turnigy watt meter ( I didn´t choose yet)
1x Red Urethane (http://crcind.com.au/red-urethane) Looking for something that do the work here in Brazil.
I will try something like this (portuguese link) http://www.mgpeletrica.com.br/loja/isolasil-tintas-vernizes-solventes/1041-verniz-isolante-iso-1723-1301l.html


My concerns: I am pretty sure, that I am forgetting a lot of things to buy.

Thanks. Any help is welcome.

 

[dogman dan]

Cheap bullets use a crimper. The kind we tend to recomend, 4mm or larger are soldered on. That's the only thing I spotted.

 

[ryanstev]

Shoplist so far.
4 x 7s 5AH battery ( done, waiting arrival)

In case you don't know (I didn't) the Zippy Compact 7S packs come with dual balance plugs, one 4s and one 3s.
I'm not sure how you balance charge with those plugs, except that you can't plug in both balance plugs when you do it, it'll short.

I bought two 7s plugs and cut the ends off the balance plugs (one wire at a time) and crimped them onto the new cable.
While I was waiting for the 7s plugs, I cut the red wire off the 4s connector and covered the end, as it's not needed and trimmed the balance plugs so I could fit both plugs into a standard 7s balance port.

 

[marcos7007]

OMG!!! I will have the same problem lol.
Now I know, and thanks to you.
I will do that.
I didn´t understand how to transform the connectors. But I hope I can do this when I see the battery or find some tutorial.

thank you very much.

 

[ryanstev]

Here's the page I used when I made my modification to the balance plugs.
http://www.rcgroups.com/forums/showthread.php?t=1610267