Project build thread. Diamond back overdrive EV

Well a whole lot done on this. Ordered another 8 x 4s 5000mah turnigy hard packs. I have 1 low cell if all cells are 4.00 it is 3.90 always even so it may be fine, but I'm going to pull it out. I have it as the easiest battery to pull. So that will leave 7 hopefully good batteries. So I'll at least throw 10 Ah more on the rear carrier which I finally got mounted today.

Don't want to give too much away but I'm rather happy with this build. New freewheel will be here tomorrow so hopefully it goes on with no issues and lines up right. It is a 7spd with an 11t gear on it so that should help. Going to see where I'm at with my cadence speed when going full out. Test run I took it on the other day with no chain it did 25 to 27 and pulled up my pretty steep hill at no slower than 19 which is really good cause the hill is rather steep. I'm anxious to hopefully get a ride on it tomorrow since it is going to breach the 30 F temp mark tomorrow after nearly two weeks hovering around 0.

I came up with some rather cool things in this build. I spent a lot of time trying to design this for simplicity of access, and still be secure. I think I did that and though it is probably costing me as much as a middle to upper end company made bike it has just about everything I wanted. And with the 30Ah I really have enough if I wanted to throw a front MP3 on if I find I'm wanting more umpf.

I'm going to run the internal controller for the time being. I'm thinking of switching to a Lyne 18fet if I can get one. Have paint on hand to do my touch ups and coverups of the logo on the downtube. Once everything is fit and finished I'll be redoing the vinyl on the clamshells and making sure everything is pristine before i go ride it all over and beat the hell out of it hehe.

Finished up wiring the lighting system. Have 3 levels of low medium and high beam. Ridiculously bright. And bought individual LEDs to build my turnsignal and tail lights. Not sure if I'm gonna bother with brake lights or not. Have the cruise function wired into my headlight switch and turnsignal switch. Used the momentary horn button. The bike has 12v on board along with USB power as well to power the tablet. Had an issue with the speedict and am waiting on the new one. Worrying about sending the dead one back later and risking it being fixable. I am probably just going to have them send me a second one so if it dies I have a backup.

Working on a pvc sheet formed front faring. So far I'm happy with it, but if I can't get it exactly how I want it I might scrap it for now. If I pull it off it will be vinyl covered to match the clamshell. Have to spend some more time tomorrow with the heatgun and slowly bending and molding it till I get it exact. The nice thing with this pvc sheeting is it is easy to cut, easy to heat and bend how you like, and its nice and rigid after it cools. Also super light and will add next to nothing to the weight. I made it to block and cover the wind in front of my hands as well. I also bought Ram system mounts and a locking holder for the tablet. Everything locks securely on the bike. The clamshells are actually using heavy duty marine grade plastic piano hinge. They also have a button near the inside toward the front of the triangle on each side. These were pricey but worth it. I think 20 something a piece, but they are nascar approved to hold hoods on at 200mph. They hold down 150lbs each. So at the touch of a button the clam shell swings open.

I haven't been doing pictures like I was of the build. There wasn't enough interest or replies and some of them were insulting. So hard to get excited about sharing. The clamshells will have a front signal assembly on each side that is riveted to the clamshells. The front signal assembly will come out in front of the handlebar stem. They are made of wood but not quite done shaping them yet. There is a hole on the left and the right where a trailer receiver lock goes through to lock the clamshells from being opened when not needing access. Still have a few things to work out on that, but should have that part done in a week or so as well. Figuring on being fully completed before March 1st. (of course I know I'll tweak things lol)

Still on the list is deciding on a final charging setup. I have all 12 of the balance lead extensions cut into a pcv sheet that fits into the battery frame in the triangle. I also have all the battery power wires coming through there and then the harness attaches ... well... you'll see.. lol So not going bms I don't think. So thinking parallel board and I want to try to do this with just 1 charger that will handle up to 16s in case I want to switch my pack around once I move on to an external controller.

QUESTION ..... If you had 20 total 5000 Mah turnigy 4s hardpacks and a Mp3 what config would you run? Currently 48v 12s using 12 hardpacks. 1 has a runt cell but not too bad so far, so 19 hopefully good to go. I'm open to buying 3s or 5s packs as well. For now with the internal 60vish limited controller.

Oh if anyone has a controller that they are selling that might be a good choice to juice things up a smidge let me know. If I'm going to swap it out though has to be worth the swapping out performance wise. Sorry for the novel. Hope at least a few people are reading this. I know these type threads are what I loved when I couldn't start buying my stuff yet.
 
babyhughie said:
Great build my friend... I'm really looking forward to seeing the finished bike..


I might try to do some pictures today, if not by the weekend. Thanks for the interest. :)
 
After spending more time than I planned to get the chain all untangled... Got freewheel mounted and took it for a spin. With the 11t gear I was able to pedal quite well up to 30. Which is about the max at the moment. Plus I'm in winter shape gonna take a week or so to get my legs back. lol If it was warm out I'd probably take it to do some errands tomorrow to test it out.
 
rborger73 said:
One simple and lovely fix would be have an orientation lock and horizontal mode on every screen. There is one screen that will give me most of the info and is horizontal but font size control and a little more tech looking speedo screen would be nice. There may be those things and I haven't found them or there is add ons I don't know about.. ttfn..

slide screen (live view) horizontal with automatic font size will be added this week.
 
speedict said:
rborger73 said:
One simple and lovely fix would be have an orientation lock and horizontal mode on every screen. There is one screen that will give me most of the info and is horizontal but font size control and a little more tech looking speedo screen would be nice. There may be those things and I haven't found them or there is add ons I don't know about.. ttfn..

slide screen (live view) horizontal with automatic font size will be added this week.


Excellent. My tablet is mounted horizontal so I have to turn my head sideways to get it to the data graph screen in live view lol.
 
just because the voltage is low on one of the pouches is no indication it is defective.

you mentioned on another thread about how you had 'runt' cells but the resting voltage of a pouch that just arrived from hobby king is no indication it is defective.

you have to test the pouch to determine if it has reduced capacity. you have just thrown away a useful pouch for no reason, and likely through away many other perfectly good pouches if you did this to other batteries.

i have never had a bad pack from hobby king. maybe this is why you guys think HK is so bad if this is how you decide if there is a 'runt' cell in the pack.

not sure who told you to do this but it was really bad misinformation.

plus you bought the hardcase packs which really have no place on an ebike. they are for the RC cars and planes which wreck.
 
dnmun said:
just because the voltage is low on one of the pouches is no indication it is defective.

you mentioned on another thread about how you had 'runt' cells but the resting voltage of a pouch that just arrived from hobby king is no indication it is defective.

you have to test the pouch to determine if it has reduced capacity. you have just thrown away a useful pouch for no reason, and likely through away many other perfectly good pouches if you did this to other batteries.

i have never had a bad pack from hobby king. maybe this is why you guys think HK is so bad if this is how you decide if there is a 'runt' cell in the pack.

not sure who told you to do this but it was really bad misinformation.

plus you bought the hardcase packs which really have no place on an ebike. they are for the RC cars and planes which wreck.

Its been cycled and charged on balance charger several times. I set the ones aside that have a large variance. I didn't say anything about throwing them out at all. Just not going into my triangle pack. Would it make logical sense to put in packs that may catch fire or have to be pulled out from a pack I've gone to great measures to not have to pull apart? lol I'm not sure why a hardcase pack is a detriment to keeping cells from accidental puncture. I'm fairly sure that is your opinion on them as well. Many others recommended them. I'm going to be building 18650 packs for it later this year if I have issues with these. I see plenty of people with thousands of miles on the same packs. So I'll just hope for the best. Some weird Pc/apple Chevy/ford like fan boy arguments around here I've noticed. lol
 
Quick ride today 6 mile lil zip around. Top speed of 29mph average moving around 21mph. If any one is interested here is the chart from the ride. Hit the play button and might have to hit the back button but should show you the chart over the ride. Think at the end the increased Mah was from the rear carrier rubber grommet started rubbing the chain. Will be fixed so it can't happen again. http://chart.speedict.com/?weblogid=363651ZL01015101
 
Here are some new pics of putting the rear carrier together. Decided to just keep it on the bike all the time. Makes it easier to fit everything I need. Getting closer.

45.jpg


46.jpg


47.jpg


48.jpg

Bottom corner of the triangle box isn't on there right now. Bottom piece is what locks it all in place.


49.jpg


50.jpg


51.jpg
 
What you see here is slid inside a metal box that will be attached to the rear carrier with security bolts and most of the time this will rarely be seen. The metal box in the front will contain a precharge module that is hooked to a 3 position key switch. When in the ON position it will feed power to the 12v module and the controller for the motor. In the ARMED position it will only supply power to the 12v module and the security system. In the OFF position the batteries are disconnected for storage. Getting close now. Come on more warm weather so I can get out to put some more miles on it.
 
Looks like you got some capacity on the bike now. How many a/h at what voltage is it now?

I'd be scared of breaking the tablet, I fall off quite regularly :D

I'd also be side tracked looking at that tablet. Sometimes i find just glancing away at something at ebike speeds is dangerous.

Be nice to watch a video on though at the traffic lights :lol:
 
I just glance down at it for speed and volt readouts hehe. Also have the headphone jack routed to back by the seat post. Have onboard usb power as well. Only thing right now separate is the front headlight but I can charge that battery on or off the bike. Has 4 18650 batteries anyways.

Have 30 Ah 12s in 4s turnigy 5000 mah bricks. I can easily fit 10 Ah more on the back if I need and could fit another 20ah in a pelican case. Gonna see what kind of range I get off these for now. I'm 65 to 70lbs total at the moment.

The tablet btw is in a Ram holder. I can literally pick the bike off the ground with the holder. It locks in place as well with a key. The alarm is a 2 way pager motorcycle alarm. Someone gets near it and my keychain lets me know. Gps tracking also buried in the bike someplace. I'll never be more than 300ft from it when it isn't locked up at home. ;)
 
deffx said:
Should change your forum name to inspector gadget :D

Well done on fitting and wiring all that up so neatly, can't wait to see what else you install, microwave for snacks? :D

Hehe thanks. Just about everything that will be on board is there now. Just the metal box that slides into left and possibly a front fairing I have partially finished. The top part of the rear carrier with the modules isn't screwed to the lower box yet either so everything will be a bit tighter looking. The wiring between the rear carrier and triangle will be protected by a metal conduit flexible pipe covered with probably black shiny pvc hose. Trying to eliminate anyplace that could allow wiring to be compromised.
 
Hey rborger73,

Nice build. I am curious to see how those quick releases work out. I would like to modify my enclosures, because I have the same problem where I have to remove many screws to get access. The problem is I want to still keep it fairly water tight/water resistant. I had a problem a couple of months ago and did not realize I had blown the main fuse that powers the controller due to the fact I have a separate fuse running the ignition wire. When the ignition wire has power, but not the main power lead the cycle analyst still lights up which I was not aware of. I will probably create a separate post regarding this later. Anyway my fuse block was behind one of these panels and almost started a fire but I had no idea because I had it so well sealed and was too lazy to remove it.

Let me know when you make it out to Denver, maybe could meet somewhere and exchange some ideas. I have done a similar build trying to have high aH capacity and decent speed to take me 20 miles one way to work, 40 miles round trip. It worked well for 1200 miles, but I have been down since November due to one problem after the other. I am using headway batteries and have 32 cells total on my system. Problem it is back heavy. Right now I am trying to replace my rim, because I could not get it trued and that is turning into its own story.

Good luck and let if you make it out here,

Ed
 
Just little video I did while testing the headlight out since it was actually warm enough outside and no snow finally. lol Still a lot to finish up on it. Mainly cosmetic now. Still working on how I'm doing the rear hinge for the clamshells. I may 86 the hinge idea and order 2 more of the button releases. Still working on the rear box that the battery and components tray slides into. It will be in the matching vinyl as well. Anywho just a really short preview of barely bumping the throttle in the driveway a little. Once all the cosmetic stuff is 100% I'll do a proper video and lay out all the features and what not.

Did 39.5 miles with juice left 2 days ago. Was pedaling some but was pushing it pretty hard. I'm around 14.5 Wh/m. From looking around that seems like a pretty good number. Still learning all the ins and outs of the Speedict. Very glad I got it.

[youtube]MCly-gtgDvE[/youtube]
 
Been a while since an update. Have been riding it as often as I can with the weather. Still managed to do better than 500 miles this year. Only time I had to pedal it home is when I left the controller cutoff set too high and forgot. Didn't have the cable and a laptop handy so I pedaled home 2 miles very early in my conditioning to getting back into spring and summer shape. lol Did a quick video of riding it. Not a lot of video of the bike itself yet. Just about happy with the fit of everything, and have to finish the front caps for the clam shell with the front turn signals. Once that is done I'll clean everything up and smooth out any issues and put on new vinyl covering and finish painting over the Overdrive and the white bar down the main tube. Have the expected scratches on the frame to refinish. Not a big deal just making sure everything is how I want it first. Still have to finish the metal box for the rear carrier.

OH btw if anyone know of a locking cover similar to a thermostat locking cover, but smaller. Looking to leave the main power breaker easy to get to. Want to find a weatherproof cover with a actual key lock, not a padlock style, but a key in a lock. That way I can lock the switch so people can't fuss with it. Down to the rear carrier box in its final form. Currently in box made out of pvc sheet which will slide inside the metal box keeping batteries, and speedict, and power convertor modules hidden and kept from bouncing around. I'm more than happy with this. Did 30 miles this afternoon and another 25.5 this evening for a total of 55 miles. Have yet to see any cell below 3.75.

Anywho if anyone has an idea on a nice solution to keep the breaker covered and locked but accessible with a key speak up.

OH and come on... I put Hysterical dog shenanigans happen at the end of this video.. must watch... must see... "best video yet this year!" says 'Rolling Stone'. Drama...action....thrill... romance... adorable puppies... high speed action...wild animals, country roads, trucks.... pretty much the making of a great Country romance and thriller movie...... think of Dukes of Hazard, the Notebook, and Die hard 3 all rolled into one...
If you see one movie produced by Ryan Borger this year... this should be one of them....
https://vimeo.com/92469524

Oh so I should at least get some "High fives" or "Nice vids" or even "You sucks"... lol sometimes it seems hard to get replies up in here. ;) In love with Ebiking...... It might be taking over.....

Here is the youtube version as well. Vimeo probably has the edge on quality. I need to play with my compression settings a bit to make them slightly better to mesh with the online vid sites. Vimeo is close to the true quality of the vid. If anyone is interested in a knock off gopro that franky so far has kicked ass and is only 159... give this a look.

http://www.amazon.com/gp/product/B00HH5DDCI/ref=oh_details_o04_s00_i00?ie=UTF8&psc=1

[youtube]En5kvhSIhQg[/youtube]
 
CAn you show your Battery charging set up? How the hell you charge all these packs all at once? and what safety measures do you use?
Do you tak the batteries apart everytime you need to charge?
 
tomtom123 said:
CAn you show your Battery charging set up? How the hell you charge all these packs all at once? and what safety measures do you use?
Do you tak the batteries apart everytime you need to charge?

Right now I'm bulk charging all at once. I put a meter on one battery as I charge usually. I've found as long as you don't run them super shallow they don't need balanced. I've got probably 15 to 20 cycles and close to 400 miles and if the low is 4.15 the high is 4.18. Only out by .03 and honestly they probably were out .03 when I balanced them last. The triangle clamshells come off by pushing two buttons. Then I check each 4s brick. I do this ever 7 or 8 cycles.

I charge to about 4.15 to 4.18 and discharge to 3.75 at the lowest. My wiring harness was done right so other than whatever tiny bit of resistance there is between the furthest battery in the front to the furthest in the rear isn't a problem. I have a charge port and use a 12 Thunder 1220 balancing charger but just charge in bulk. I've been extremely cautious with this setup. I'm waiting for speedict to finish their controller / bms setup to go with my Speedict mercury. I planned on doing a db25 setup for the balance charger but the way I charge and monitor I've decided to wait for the speedict controller bms. I want to see a bms display along with the stuff I do now. Going to have to email Danny about an update on that.

There are 18 4s bricks. Put in packs of 3 for 5Ah per pack. For a total of 30Ah. I don't normally even take the sides off. I have some jst extension cables one for the triangle and one for the rear carrier. Charging and figuring out a setup is kind of a nightmare, and around here it always deterioates into a bms vs no bms, lipo vs whatever other chemistry, Rc chargers being toys, blah blah. I'm very happy with the bang for the buck these batteries give me. I take care with them, but my batteries don't move even an 1/8th inch. The harnesses don't come unhooked. Everything is secure. I will feel a bit better when I have that bms and controller setup and am able to better monitor at least cell averages. I'm hoping for being able to see all 72 cells but I know that is unlikely. ;)
 
This thread may help some. Just takes reading a ton and learning as much as you can.

http://endless-sphere.com/forums/viewtopic.php?f=14&t=58321
 
Good looking bike. Looking forward to pics of the finished version.

Saw earlier in the thread you talked about weight in the 65-70 lbs category. Have you done a final weight now that you have everything final/close to final? 70 lbs or less with all that battery power and gadgetry is impressive!
 
the_dude said:
Good looking bike. Looking forward to pics of the finished version.

Saw earlier in the thread you talked about weight in the 65-70 lbs category. Have you done a final weight now that you have everything final/close to final? 70 lbs or less with all that battery power and gadgetry is impressive!

I'll get on the scale with it tomorrow. It isn't that difficult to pick up and swing around. I don't think I'm over 80lbs.
 
Ended up doing 55.1 miles yesterday. Full charge to start, ran it down to 3.9 per cell then charged for about an hour after doing 30 miles, then did another 25 miles at pretty much full throttle the whole time since it was getting close to sunset. I think this week or next I'm going to do 100 miles over a full day to see if I can do it. Have a pair of padded shorts coming to make it easier on the the gluteus maximus..

This btw is working wonderfully. Just got it and since I monitor my charging via webcam from about 60 ft away this is nice so I can avoid having to get up when it is topped off. Worked through about 4 walls and 5 rooms away with np.

http://www.amazon.com/gp/product/B001Q9EFUK/ref=oh_details_o03_s00_i00?ie=UTF8&psc=1
 
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