Methods,
Sorry to hear about your wipe out. Sounded like a pretty catastrophic failure. I am not one to preach, but here goes a little anyway, not just for you but for all newbies out there contemplating how their new ebike projects should take shape....
Due to the fact that we are essentially slapping high power drive systems on platforms that were engineered (by real engineers, I might add) to be used ONLY with human powered stresses and inputs, it is crucial to make sure that the conversions are done in a way that insures against failure due to material fatigue.
We had some nice weather here in the burgh yesterday - 45 and sunny, so I decided to take my bike out for a little romp. Whil e it was charging in the morning, I was going over the machine, and decided to increase the seatpost height a smidge, level the saddle out.
I found that the seat post was CRACKED where it clamps to the saddle rails, on both undersides. This was due to several issues:
1. The seatpost was a Kalloy aluminum brand post, designed to be used with a lightweight MTB saddle
2. I use an Azonic DH saddle on the post, and slid the saddle BACK as far as it can go for more room in the cockpit. The seatpost was not designed to be used with this saddle, as the leverage my 180 pound frame sitting on the back end of the seat was causing some serious stress on the clamping mechanism.
3. The combination of the two items above were a formula for eventual failure, but the time required to reach failure was exponentially decreased due to the increased speeds, increased mass and increased force I am now hurling through time and space at. Took about 1800 miles on my e-set up. Probably could have went for 5-10 years under pedal power only.
Post in th arse. That would not be fun....
Be safe. Over-engineer your systems if you're going to run as much power as you do on mayhem.
Peace,
Len