Turnigy 80-100 Build - Made in the Netherlands

[bart1006]

I’m reading this forum frequently for quite a while. Now it is time to make my first post and
introducing myself and my ebike
Just to share some information about my ebike build instead of just reading

Parts:
- Turnigy 80-100b 130KV (bought it from some students, they tried to use it for their solarboat http://solarteamwindesheim.nl)
- An old computer PSU, changed it for the battery charger.

Hobbyking:
- 1x TURNIGY MEGA 380W Lithium Polymer Battery Charger
- 6x Turnigy 5000mAh 5S 20C Lipo Pack à 63V 10Ah
- 1x H-King Cellmeter-6 Lipo/Life/Li-ion Cell Checker & Alarm
- HXT 4mm Gold Connector
- Turnigy Pure-Silicone Wire 10AWG
- JST-XH 5S Wire Extension 20cm

sdp-si.com:
- A 6C 7-25B72 - 0.25 (#25) Pitch, 72 Teeth, 0.5" Bore, Metal roller chain sprocket
- A 6Q 7-H25 - 0.250" Pitch heavy duty hardened steel roller chain
- A 6X 7-2514 - 0.25 (#25) Pitch, 14 Teeth, 0.25" Bore, Metal roller chain sprocket
- A 6Q 7-H25SCCL - Spring Clip pitch, Hardened Steel Roller Chain Type Connecting Link
- S40PX0-CHS4-011 - 0.5" Dia., 5.50" Length, 420 Stainless Steel, Shaft Case Hardened (Rc 52-56)

EPBuddy:
- ParaBoard-XH with 4mm Bullet Connectors 40A Version

Ebiks.ca:
- Cycle Analyst

Eclipsebikes.com:
- 3 Chainwheel 48T (freewheel), 48T, 32T
- Cranks
- Chainguide

Forum members:
- 12 FET controller (Lyen)
- Throttle (Lyen)
- 0,5" freewheel adapter (Matt)
- Hall sensor mount 120deg. (Gwhy!)

Other:
- Some aluminium for the frame (aluminiumshop.nl)
- Freewheel (local bike store)
- Ball bearings (ebay)

The overall reduction is:
- 1st stage: 14 - 72
- 2nd stage: 16 - 48
- 3rd stage: 32 - 20(?)
So the ratio will be around 1:9,6 - no idea if this is a good ratio it will be a little bit try and error :wink:

All the feedback are welcome!!

Picture timeline: (lost a lot of pictures because of a migration to my new mobile)

a couple of the parts from sdp-si!!


drilled out the little sprocket to 12mm for the motor shaft and add some "security" bolts


View attachment 16


the aluminium plate (and some of my other junk)


building the mount, it wasn't right-angled so adjusted it a little bit



View attachment 10
View attachment 9




getting nervous


the bike and adding all the stuff together


removing the crank ain't got the tool for it


View attachment 1


This week i will post some more photo's but for now i reached the max number of pictures

 

[Lebowski]

looking good And thanks for the link to sdp-si..

Volgens mji zit er nog een Nederlander hier van ES vlak bij jou in de buurt...

 

[dingoEsride]

Volgens mji zit er nog een Nederlander hier van ES vlak bij jou in de buurt...

I believe that there is another dutchie here in ES nearby in your neighbourhood

He! He! just brushing up on my dutch, oh and nice build should go well

 

[bart1006]

looking good And thanks for the link to sdp-si..

Volgens mji zit er nog een Nederlander hier van ES vlak bij jou in de buurt...

I think you mean Byte! He helped me a lot in the begining and i saw his Bergli post yesterday awesome!! (dingoEsride can you translate this to dutch? )

 

[Lebowski]

looking good And thanks for the link to sdp-si..

Volgens mji zit er nog een Nederlander hier van ES vlak bij jou in de buurt...

I think you mean Byte! He helped me a lot in the begining and i saw his Bergli post yesterday awesome!! (dingoEsride can you translate this to dutch? )

nee, d'r is hier nog iemand die op het Windesheim zit... Die zal zich nu wel goed boos maken op de bootjesclub dat ze de motor niet aan hem gegeven hebben

 

[MAGICPIE3FOCUSPOWER]

NIce build!

I hope the Dutch police will not pull your off.
It happens me several times and I don't have mid drive system....

 

[nieles]

hehe yea is have seen the the motor around. nah not that angry lebowski.. i already have 2-3 of them

if you need any help with the controller, shoot me a pm. maybe i can help (with these low inductance motors, sometimes the controller will cut-out when you want to accelerate fast. this can be fixed with a small mod)

 

[Lebowski]

hehe yea is have seen the the motor around. nah not that angry lebowski.. i already have 2-3 of them

if you need any help with the controller, shoot me a pm. maybe i can help (with these low inductance motors, sometimes the controller will cut-out when you want to accelerate fast. this can be fixed with a small mod)

Do you still use the controller based on my controller IC ? How is it ?

 

[bart1006]

hehe yea is have seen the the motor around. nah not that angry lebowski.. i already have 2-3 of them

if you need any help with the controller, shoot me a pm. maybe i can help (with these low inductance motors, sometimes the controller will cut-out when you want to accelerate fast. this can be fixed with a small mod)

Oh right thanks for the offer! Saterday i had a little test drive and broke something it looks like my motor is cogging a little bit now.
I'm not certain what the problem is but will start with change my bearings because they have had their best time

 

[bart1006]

NIce build!

I hope the Dutch police will not pull your off.
It happens me several times and I don't have mid drive system....

They probably will :wink: what did they say when you were pulled over? did you get a fine?

 

[gwhy!1]

hehe yea is have seen the the motor around. nah not that angry lebowski.. i already have 2-3 of them

if you need any help with the controller, shoot me a pm. maybe i can help (with these low inductance motors, sometimes the controller will cut-out when you want to accelerate fast. this can be fixed with a small mod)

This no longer happens with the new spaced hall sensors as long as they are setup correctly .

 

[bart1006]

Just another update!!

The battery box:

View attachment 10




I added a chain tensioner which i bought from eclipsebikes.com and aligned the chain:


View attachment 5


Now my shaft was to short so i ordered a new one at sdp-si.com but for now made a temporary shaft:




Then i made a test ride:



...... and broke something the motor is not running very smooth anymore. Ordered some new bearings hope that it will solve the problem.

 

[fizzit]

If you haven't already, it might be a good idea to make sure that the motor phase isn't shorted to stator. I like your battery box, it looks very clean.

 

[Secret1511]

Hoe hard gaat ie? How fast does it go?

 

[bart1006]

If you haven't already, it might be a good idea to make sure that the motor phase isn't shorted to stator. I like your battery box, it looks very clean.

Thanks for the tip!

 

[bart1006]

Hoe hard gaat ie? How fast does it go?

I'm not sure yet for the test ride i didn't hooked up the speedometer. Next time i will do that and let you know!

 

[dingoEsride]

Looking good Bartdude , you have skill full hands and the turnigy motor tops it off nicely,

I think you mean Byte! He helped me a lot in the begining and i saw his Bergli post yesterday awesome!! (dingoEsride can you translate this to dutch? )

Ik denk dat ye Byte bedult, he hept mei an handt geven iederer ah earlier nah too hard english is hard enough,
I had an uncle in Amsterdam who I stayed with for a few months, cycling around there is such a hoot, and travelling from town to town hiring a bike at the station made traveling a breeze

 

[pendragon8000]

nice.

3 stage rdustion is prety full on. but you kept it so compact.

hows the motor now?

 

[neptronix]

Absolutely awesome.
Please get videos of the result

 

[bart1006]

An update about the motor:

It didn't run smooth so i did a few test with another forum member Nieles (which i found out was practically my neighbour) to check if the problem was my motor or my controller.

View attachment 19

We found out that one of the phase wasn't as good as the other two (thanks for the time and effort Nieles)
After that i did a check on the stator with the multimeter, if it hadn't a short circuit with one of the phases.
This wasn't the case so the only option was to re-wind the motor and hope for the best :?
Thanks to mauimart and Thud for the information about the re-wind diagram and materials:

wire 1,5mm copper:


Kapton tape:


Schema: (9 turn WYE - STAR)


The pictures of the rewind proces:
View attachment 15





View attachment 9
View attachment 8









I did a test yesterday and the motor is running smooth again and it doesn't become hot anymore while testing!!

 

[Lebowski]

it looks to me like you could have easily fit 5 more windings onto each tooth, no ? More copper is always better !

 

[nieles]

That motor looks very beautiful! Nicely done!

 

[gwhy!1]

it looks to me like you could have easily fit 5 more windings onto each tooth, no ? More copper is always better !

and would have slowed it down even more.

 

[Lebowski]

it looks to me like you could have easily fit 5 more windings onto each tooth, no ? More copper is always better !

and would have slowed it down even more.

Which can be fixed.
A higher voltage battery. Or wind two strands in parallel and terminate in WYE.

 

[bart1006]

it looks to me like you could have easily fit 5 more windings onto each tooth, no ? More copper is always better !

and would have slowed it down even more.

Which can be fixed.
A higher voltage battery. Or wind two strands in parallel and terminate in WYE.

This was my first rewind, so maybe next time more copper. Is there somewhere more information about the results for winding in parallel?