Raptor 140 - Full Suspension eBike Build Thread

Yep, I got 2 Fox 40 Floats sitting in my dining room. :mrgreen:

I am thinking 10.5x3.5 on my bike and may use a 9.5x3.0 (Fox CTD) on hers with an air spring so I can adjust the pressure when I or other ride it.

EDIT: Ended up picking up a 10.5x3.5 Fox Van RC for the wife's bike.
 
Got frames and some parts! Still missing a bunch of stuff but I'm working on it.
 

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A little more progress. Spooned my first tires today and yes... I scratched the rim a couple times. :cry:
 

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Pretty much stalled since my last update. I have the derailleurs but they are rubbing the motor. I am having the rear brake caliper mount machined down this week so I can shim everything to the left (more centered). Right now, it is shimmed off center to the right to make room for the calipers and fat vented rotors. I didn't like this anyway so hopefully the skinnier mount won't be too weak. I am taking it down to half its original width in the areas that touch the swingarm. I'll post some photos when I get it back Friday.

I still have all the wiring to do as well. If I get some relief from my work schedule, I'll make a bit more progress.
 
very nice components you have picked! I am following some of your build.

Voltriders.com has closed down, do you have any recommendation for Rim Drill and Spoke Lacing ?
 
Mammalian, can you do me a big favor.

Could you attach the motorcycle footpegs and take a side view of the bike.

I'm trying to determine if the footpegs sit below the bottom bracket and will help protect it on bottom out.

I am also trying to determine if I should have qulbix make a small skid plate that attaches to the footpegs and maybe the kickstand bracket. I will have to ask them to reinforce these areas, especially the kickstand bracket.

It almost looks like the footpeg bracket is flat and will hang up on things, instead of sliding easily over it.

The kickstand bracket is kind of useless anyway because the bike is too high to work with any kind of kickstand there.

Thanks.
 
BCTECH said:
Voltriders.com has closed down, do you have any recommendation for Rim Drill and Spoke Lacing ?
Holmes Hobbies is owned by the part owner of Voltriders, John Holmes. John took a break from lacing but he might be back at it under Holmes Hobbies. They are slow but everyone says they do the best eBike work if you are central or eastern US.

Offroader said:
Could you attach the motorcycle footpegs and take a side view of the bike.

Yep, give me a half hour or so.
 
Mammalian04 said:
COMPONENTS
This is where I will build my list of proposed components and the anticipated vendor (after the "-"). Confirmed component selection will be in BLUE.

Component Group A
Motor:
*- $595 - Cromotor V3 rear hub motor - Zombiess (greyborgusa.com)
Controller, BMS, and Charge Coil:
*- $800 - Adaptto MaxE with display
*- $105 - Adaptto MaxE BMS
*- $50 - MaxE charging coil
*- $35 - Shipping Cost from Russia
Batteries:
*- $1404 shipped for 16 packs - HobbyKing Zippy LiFePo4 4s2p 8400mah 30c - 8 packs in each bike for 16s4p in each bike
Custom Harness :$435 total ugh...
*- $80 - 4 series 2 parallel custom harness - Icecube
*- $180 - 6 series 3 parallel custom harness - Icecube
*- $30 ($15 each) precharge - Icecube
*- $24 ($12 each) 250a circuit breakers - Icecube
*- $41 Misc. connector and wire charges (XT150, 8awg controller wire, 10awg battery wire, 5.5mm bullet connectors, etc)- Icecube
*- $79.84 - 16 2x Parallel JST splitters (HK out of stock) - Icecube

*- $165 - Server Power Supply - Mean Well RSP-1500-48 - Vetco.com

- Samsung 25R - 20s13P - Five 4s13p wired in series
- Battery assembly kit (fuse for 25r high discharge) - Circuit
- $330 new / $? used - Eaton EPR48-3G Rectifier Power Supply - (900W 48Vdc 208/240 Vac Input 550W At 120Vac Input)

Component Group B
Front Wheel 1:
- $110 - 19x1.4 Motorcycle Wheel - Prowheel Racing
- $? - 13g spokes - Voltriders.com
- $55 - Spoke Lacing - Voltriders.com

Front Wheel 2:
- $140 - 19x1.85 Motorcycle Wheel - Prowheel Racing
- $? - 13g spokes - Voltriders.com
- $55 - Spoke Lacing - Voltriders.com

Rear Wheel 1:
- $110 - 19x1.4 TTR - Prowheel Racing
- $108 - 8g spokes - BuchananSpokes.com
- $136 - Rim Drill and Spoke Lacing - Voltriders.com

Rear Wheel 2:
- $140 - 19x1.85 - Prowheel Racing
- $108 - 8g spokes - BuchananSpokes.com
- $136 - Rim Drill and Spoke Lacing - Voltriders.com

Front Tire:
- Shinko 19x2.75 SR241 - MotorcycleSuperstore.com
Rear Tire:
- Shinko 19x2.75 SR241 - MotorcycleSuperstore.com
- Shinko 17x3.00 SR241 - MotorcycleSuperstore.com
Tubes and Rim Strips:
- Bike Master Tube 19x2.75 - MotorcycleSuperstore.com
- Bike Master Tube 17x3.00 - MotorcycleSuperstore.com
- Rim Strip 19" - MotorcycleSuperstore.com
- Rim Strip 17" - MotorcycleSuperstore.com

Brake Calipers and MCs:
- $540 ($269 Each) - Magura MT7 4 Piston (Right hand for front brake but lever can be reversed) - Amazon - Phat Tire
- $330 ($165 Each) - Magura MT5 4 Piston (Left hand for rear brake) - Amazon - Xtreme Bike & Sport or Cycle Progression(local shop)

- $460 ($230 Each) - Avid Code (4 Piston) - Price Point / $455 on Pinkbike with 200mm/200mm F/R disks
- $245 ($122.50 Each) - Avid Code R (4 Piston) - Chain Reaction Cycles / $355 on Pinkbike with adaptors and any size disks
Brake Switch x2 for each bike:
- Reed Switch
OR
- $29 - Magura Hydraulic Pressure Switch - LINK
- eBike.ca throttle with button - eBike.ca
Brake Discs:
- Front Disk - 203mm - Cycle Progression
- Rear Disk - 203mm - Cycle Progression
Brake Pads & Oil:
- mineral oil or dot5 (dependent upon brake options) - Cycle Progression
- Organic or Sintered brake pads (dependent upon brake options) - Cycle Progression
Frame:
- Raptor - Qulbix

Seat:
- Regular Seat?

Component Group C
Rear Shock:
Bike 1 - 10.5 X 3.5
- $? - Fox DHX RC4 Kashima - Pinkbike.com (used take-off)
- $558 - Cane Creek DBCoil - JensenUSA.com
Bike 2 - 9.5x3.0
- $110 used + rebuild cost - Fox Van RC - pikbike.com
- $ - Fox Float X CTD w/ Trail Adjust -
- $550 - Cane Creek DBAir CS - AEBike.com

Forks:
- $999 - 2014 FOX 40 FLOAT 27.5 RC2 - jensonusa.com

- $555 - DNM USD-8 with dual brake disk mount - Zombiess - (greyborgusa.com - Out of Stock Indefinitely)
- $425 used (stem cut?) - Rockshox Boxxer - ES forum
- $ - Marzocchi 888
- $1350 - 2015 FOX 40 FLOAT 26 FIT RC2 Kashima - pinkbike.com
- $900 - Manitou Dorado Expert (air spring) - pinkbike.com

Head Set - 44mm headset internal diameter (1 1/8" headset):
- Bike 1: Cane Creek 40 - Cycle Progression
- Bike 2: Hope Headset - Cycle Progression

Stem: Tall enough to mount bicycle seat bar for Ethan
- Bike 1: ???
- Bike 2: Hope Top Crown - Cycle Progression

Bars / Grips:
- Bike 1: $30 -
- Bike 2: $30 -

Brake Levers: Not Used
- $? - eBrake - ilia

Front Hub:
- $89 - Hope Pro 2 EVO 36h - Front Hub - Chain Reaction Cycles
- OUT OF STOCK EVERYWHERE (grr....) - $75 - DNM Dual Disk Hub - Voltriders.com

Crankset:
-

Pedals:
- $55 - Shimano Saint MX80 Pedals - Chain

Throttle:
- ebikes.ca throttle with momentary switch
- ebay throttle with on/off switch

Component Group D
Charging Port:
- MaxE Charging port for 5v USB (iphone, iPod, etc)
Headlight:
- ebay headlight
Mudguards:
-
Rear light:
-
Horn/Bell:
-
Switches and Labels:
- Power Setting (Low, Medium, High) - on Adaptto MaxE display
- Lights - High, Low, Off) - ?
- Rear Lights - On/Off - ?
- Controller Key - On/Off - ?
- Regen - On/Off - ?
- Horn / Bell - ?
GPS Tracker:
-
Paint:
- Upgraded Swingarm paint to match white frame - qulbix
- LineX - Texas Truck and Trailer
Wiring:
- $9 - Charge Port - NLT4MP-BAG - Rated to 40A - 50% Duty Cycle - AlliedElec.com
- $0.85 - Charge Port Gasket - SCNLT
- $2.38 - Charge Port Cap - SCL
- $6.79 - Charge Plug - SPEAKON NL4FRX - Rated to 40A - 50% Duty Cycle - Alliedelec.com

Are you going to make a 10 000usd bike? Lol
 
I got probably around 7K to 8K in my bike, and this is for parts only. Doesn't include labor for building wheel, making battery connections etc.
 
Offroader said:
Mammalian, can you do me a big favor.

Could you attach the motorcycle footpegs and take a side view of the bike.

Offroader, sorry for the delay. I realized I didn't have a tool to get the crank and sprocket off (needs to come off for pegs to fit on) and I haven't ordered one yet. These pics are the best I have at the moment.... I need to order the right Bottom Bracket tool so I don't mutilate it with a pipe wrench.
 

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Thanks, Mammalian04.

I didn't realize that you had the cranks on! So I wouldn't remove them to be honest unless you really had to.

Do you know if the footpeg bracket sits below the bottom of the bottom bracket any? Like if you had the footpegs installed and bottomed out what you hit the bottom bracket or the footpegs?
 
Mammalian04, is there any particular reason you decided to get the swing arm painted white and not leave it black?

Do you think the bike would look better with a black swingarm instead of the white?

Could you take a picture of your white bike and post it. Maybe a 2nd shot from the side/rear to show the frame sticker colors below the shock on the frame. I am curious how the bike looks with the white swingarm.

Thanks a lot!.
 
Offroader said:
Mammalian04, is there any particular reason you decided to get the swing arm painted white and not leave it black?

Do you think the bike would look better with a black swingarm instead of the white?

Could you take a picture of your white bike and post it. Maybe a 2nd shot from the side/rear to show the frame sticker colors below the shock on the frame. I am curious how the bike looks with the white swingarm.

Thanks a lot!.

I liked the look of all white better for my Wife. Her bike will have a little more bling, as you can see from the wheels.
 

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Thanks, I'm still trying to get ideas for my coloring. I'm not sure if I want to go full orange.

Damn that's really nice.

I didn't know Qulbix made the raptor sticker in black. I would probably have gotten it in blue, as the seat mount is blue.

Did you have Qulbix paint the motorcycle seat in blue for you?
 
Offroader said:
Thanks, I'm still trying to get ideas for my coloring. I'm not sure if I want to go full orange.

Damn that's really nice.

I didn't know Qulbix made the raptor sticker in black. I would probably have gotten it in blue, as the seat mount is blue.

Did you have Qulbix paint the motorcycle seat in blue for you?

Yes, the controller guard was supposed to be blue also but they missed it on the order and I didn't notice either (so my fault for not double checking). It is black so I may just leave it off... haven't decided.
 
Actually the black controller cover may look better because right above the controller is the blue stickers. It may contrast better?

I would try it out.

I think you're always better off putting the controller on the outside, too many problems putting it internally with heat anyway.
 
Mammalian04, Well done for documenting your builds. I look forward to your update's. I believe that when you spend the amount of money that we have you have made the right decision on using Adaptto controllers. I'm enjoying my mini-e and have a max on the way. Not sure what I am going to do but may put the cromotor on my Raptor and the mini-e on the Phasor with the 4065.
 
How do you have it connected to the top of the frame Rodney and what are you using as the interface between the controller and the frame? I'm experimenting with that at the moment.
 
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