Rincon-latest build

[torker]

This is my latest build. It is either an 07 or 08 Giant Rincon. It has either 80 or 100 mm travel SR Suntour XCR magnesium forks w prelaod adj. I've googled the rig and came up with conflicting numbers. The nubs are not even worn off the tires. It's a craigslist find for 110 dollars. I've already added a 3 " riser to the handlebars and I plan on installing a thudbuster seatpost and a bigger saddle. Of course that will cost more than the bike

I've started to fit the batteries as you can see. Yes that is 24 lbs. of lead. What can I say, I already have the batteries. I want to make a support box that will bolt on the water bottle bosses. I thought I might make it so it supports the bottom and right side of the batteries and then some sort of cover for the left side. I don't have much material here so I still need to make a trip to the yardstore. Not sure if I should try to make it out of alum. (easy to work with) and light. If I do I'll probably end up with a lot of bends for tabs and such to fasten corners together, with rivets I suppose.

Any ideas welcome.. I want the enclosure simple. I hope to get it done by Wed. - my next day off and hopefully the day my kit arrives.
Throw some ideas at me guys..

 

[grindz145]

I'm always a fan of putting the mass in the frame where it belongs (not on the rack).

A particularly ghetto way I've mounted Pb in the frame is using big (6-10") hose clamps. If you host clamp all the way around the frame and around the top of the battery, the host clamp actually forms around the batteries nicely and you end up with a very strong mount. Ghetto (40z of it), but strong, and you could easily have it done in a few days. Probably would want to put some rubber against the frame so that the hose clamps don't scratch the frame. Certainly doesn't look too attractive but hey... no duct tape needed.

 

[torker]

Yea, I actually did that on my old 24V cruiser I had. They do form nicely and hold secure. Only thing is this packs a lot taller since I have them stacked. I suppose I could secure the bottom row first and strap the top one to those.

 

[dogman dan]

I found combining aluminum sheeting( old road signs I scavenged but did not steal) and wood made a quick easy battey box for fame mounting some nicads.

Start with two wood pieces along where it says giant, on the frame. Other little blocks to fill in the space the battery doesn't take up in the top of the triangle. Make all the wood pieces just the right size, that is, same as the battery blocks. Then a few holes in the sheet of aluminum and screw to the wood. Quick, easy, fast, cheap. To secure the whole thing to the frame, just a few metal straps, that again, screw to the wood. The two bottom strips of wood will need a piece of sheet metal to connect them and secure the bottom to the frame. The metal could have holes to acess the battery terminals if you like. Same thing would work with lexan sheets or plywood. If you use metal you'll need to insulate those terminals of course. Coroplast sheet mabye.

In my opinion, making the whole thing out of metal is fine, but only makes it more complicated and time consuming to assemble. With the wood bits, you can unscrew anything you need to gain access when you need it. It's just so easy to screw a sheet of metal to a block of wood.

 

[adrian_sm]

I want to make a support box that will bolt on the water bottle bosses. I thought I might make it so it supports the bottom and right side of the batteries and then some sort of cover for the left side.

Sounds pretty similar to what I have done.

Simple bit of sheet metal aluminium bent, then a few holes drilled for the water bottle mount points, plus a zip tie for a spot where a bottle mount wasn't available. Then I initially had a very simple rain cover, recently I turned an old backpack into a more refined cover.

Anyway check out my build thread for pics and mroe details. Hopefully it gives you some ideas if nothing else.

Cheers, Adrian

 

[torker]

Had a little fun with the jigsaw and welder today. What started life as an old radio chassis is now a battery tray. It was an old chassis and actually heavy enough to weld. I was able to use 3 bottle cage inserts to bolt it on. I also rearranged my batts. Two on their sides was a little shorter than one vertical which allowed me to slide them a little lower in the triangle gaining some room up top for cables. Also I was able to get all my terminals grouped close together. I'll probably look for some large hose clamps to cinch them down. So far so good. All in all a good day in the garage. After everything is mounted and wired I may make a cover. I've got a kit to install large snaps, if I can find the damn thing.. I think the controller is just going on the top bar below the seat.

 

[grindz145]

nice! But I'm going to have to take that 40 back

 

[torker]

nice! But I'm going to have to take that 40 back

Yea I owe ya that..course I'm not done yet. There will be some ductape involved.. I had everything except the hoseclamps here.

Got any pics of that 50 ah batt setup of yours?

 

[dogman dan]

Well, that certainly works fine. Having a welder and knowing how to use it definitely changes your options. I have a cheap welder, but a lot of good it does me, unless I just want to make pretty sparks. Nice work. A couple blocks of wood in there would still give you an easy way to attach side covers if you want them.

 

[torker]

Yea I'm thinking I want to put some kind of blocks in to "square" it up for a cover too.

 

[torker]

Got some hoseclamps. Still not big enough though, going to have to hook 2 or 3 together Got my charger today and my fourth battery. Yeah one battery in my pack was a junker I used for mockup. AND my kit left Lenexa Ks. today. woohoo. Bad part is I gotta drive 10 hrs. tomorrow to pick up a tranny for my sons car. 260 Z kinda rare .. What we do for our kids 8) But, hopefully my toys will be here when I get home, can't tell I'm a little anxious..eh

 

[grindz145]

Hmm I had no trouble fitting my 17ah gen cells and the frame around 1 hose clamp. They were obviously pretty large though but they were in stock at le olde corner hardware store. They were probably like 10" hose clamps. I'm not sure what department they would normally put these in for normal use :lol:

 

[torker]

Yea I got cheap at our local Yardstore. Got em for 69 cents each. Plus a bunch of other stuff I "needed" like 3 different grades of scotchbrite. material for a battery cover..etc. It's truly a manstore Oh and more zipties..

 

[TylerDurden]

Hmm I had no trouble fitting my 17ah gen cells and the frame around 1 hose clamp. They were obviously pretty large though but they were in stock at le olde corner hardware store. They were probably like 10" hose clamps. I'm not sure what department they would normally put these in for normal use :lol:

FWIW, Maxi-size hoseclamps are stocked at the HVAC suppliers, same with maxi-zipties.

 

[torker]

First ride tonight, woohoo. It is actually faster than I need to go on gravel roads. It'll do at least 20 mph. on 48 V sla. It was dark and cold so was about a 3 min. ride- no lights. It seems really quiet. A lot quieter than my 2807. All worked out of the box the first time. It won't be a wheelie machine but it really pulls hard. A lot better than the 2807 @ 48V. I wonder if they make a 5*11 or 4*12 winding? That would probably wheelie Pics tomorrow I promise, duct tape and all

 

[dogman dan]

So which motor is this?

 

[torker]

Ok, just found out about the second burp and recovery of the system-thanks Ypedal... So here are the pics of the Rincon with the 6*10 9C @ 48 VView attachment rincon rt.jpg

 

[Ypedal]

test - strange, if i post the picture exactly the way i saved it it loads as a link, if i resize it by 50 % it will load as an image.. however the picture above is double the size of the original below before i edited the size.....

 

[torker]

Thanks Ypedal. Also I noticed that u can't scroll over it and get the full size image. Oh Well, I will get the full size pics on photobucket soon. And probably some new/ better shots as well.

I have noticed that this slower wind motor seems to be a lot quieter than my faster wind. And no growl at takeoff either. Better part throttle response. Going from half throttle to full it really pulls. Also it does have a slightly softer start but ramps up quickly. No speedo yet but feels like 20 mph. It goes faster than I want to run in the gravel and loose stuff. This would be killer in a 20 inch wheel with some more volts added.

My favorite new motor

 

[torker]

Not much different. Just made my sla pack look like a ping duct tape :lol: And added a little fender just to keep the controller dry. And I added a charge connector so it is plug and play.
I really am liking this slower wind. When money allows I would like to lace it in a 20" rim and run 72 V on a full susp. frame. Then we could throw some gravel. Finally got a little more riding in. It hit almost 50 f today. It is so cool being able to hit the alleys and dirt roads now. All kinds of new shortcuts.

 

[torker]

Got another 7 mi. of dirt roads today. came across a lycra on a carbonfiber roadbike. He saw me pull out from a dirt road onto a paved county road and couldn't understand why it took him so long to catch me. He finally passed me on the flats and then I caught back up in town and talked to him. He was amazed when he saw those 2.3 inch tires bulging @ 30 psi and I was cruising @20 mph. AHEAD of him. He was 15 mi. from home. 2 towns away. I gotta give him credit. I don't go that far. Until I get some lithium. I'm pretty sure my hub weighs almost what his whole bike does.

All in all really fun. Got to see some farms with a view I would love to have. I will take the camera next time. I charged and it only took 1 1/2 hrs. @ 2.5 amps so is that 3 3/4 ah used? Probably about right for 7.5 ah sla It was getting weak towards home. Still not bad on the flats but I could tell it didn't want to pull any hills. I'll have to watch it. On my 36 v setup it would just die at a certain point because of lvc but this does not. I assume because the lvc is setup for 36 not 48 v like I am running now. i did up the tires to 40 psi. The back was bulging pretty good.

I know this is minor league stuff compared to what a lot of you do with lithium, I'll get there. The hillclimbing is almost there on a fresh charge so I figure a good pack where I can up the amps to around 30 and I will be ok @ this voltage. Good thing is that it didn't miss a beat , and I impressed a lycra on a 1000 dollar bike

 

[BrandonB]

Here's my '05 Rincon:

I broke one fork being stupid (loose nuts, no torque arm), but this one is doing fine. It took alot of time on the grinder to get the parts to work right with the funny front fork it comes with. I have put about 40 miles on it so far using six 12V 7.2aH batteries wired for 36V and 14.4aH, it's holding up pretty good too. I have a set of Richey Tom Slick tires to put on soon, and I'm eventually going to switch over to a steel front fork like a Surly 1x1 or a Kona Project 2.

Yours looks alot better thought out than mine. Hope you can use what I have done to mine so far.

 

[torker]

That is a lot of lead. I've got 4 the same size on mine for 48 v but not much range. My front fork has magnesium lowers so I decided a rear motor was the only way to go on this one..