UK Power E-bike build

[Psycholist666]

Hi,

Well I know that most people start off on here by stating the idea for the project and then following through with the build stage by stage. Well with the help of all you guys I have now built my bike and will now start to show it off on here. I'm yet to test ride it as the weather is so bad here at the moment but have built a test rig and seems to run OK but with no load so expecting problems to occur.
Bit about me. I work in Music Security, I'm a very good cycle mechanic and this time last year the only thing I knew about electronics was how to wire a plug! This project was funded by a friend with deep pockets and has changed a lot in the build and we have had to power down already!!
Original Goal:
2 x Astro 3220
2 x CC Ice2 160
CA3
Now:
1 x Astro 3220
1 xCC Ice2 160
4:1 reduction
Front Chain Drive 32 teeth
Rear Sprocket 22 teeth
CA3
with no load gets 96.3mph - still to test on road

Well will update this tomorrow with rest of build details, picture and video!
BIke:

 

[Sellick]

Very much looking forward to this!

 

[Psycholist666]

Parts List - front to back:
Front wheel - Hope evo pro 2 hub, DT Swiss Spokes, Mavic 721 rims, Shimano XT-Saint RT86 Ice-Tech 6-Bolt Disc Rotor, Shimano XT Saint twin pot hydraulic calipers, Shimano Disc Barke mount.
Forks - Fox Suspension 32 Float RL,
Head set: Hope "pick n mix" from Chain Reaction Cycles
Brakes: XT Saint - levers
Magura Full twist throttle with matching grip on left
Cycle Analyst 3 - Thanks Justin at e-bikes.ca - for inventing a great piece of kit and I'm sorry to all those members I asked dumb assed questions to.
Thumb Operated cut out swith - cheap but it works.
Frame: Boardman Full Suspension - bought on eBay for £220
Reduction: Recumpence 4:1.... more on this later but not need to think this one out before put this in writing.
Asto 3220 4 turn motor
Castle Creations Phoenix Ice Edge 2 HV 160
BB: Truvativ - will see if it holds out.
Pedals: Hope - Gun Smoke
Cranks: Truvativ
Chainset freewhell: White Industies
Chainset: 2 x Surly 32 teeth
Chains: KMC K710SL Kool Chain
Rear Wheel: Same as front - But official invoice states - Hope Pro 2 Evo Disc Custom MTB Rear Wheel
Brake rotors, callipers etc all same as front except had to do a rear hub conversion to take a Hope conversion kit that turns a 6 -10 gear cassette to a single gear cassette.
Battery - This is doing my head in - the guy who wanted me to build this almost ordered a custom built Lipo Battery before ALL of the other parts?!!! It came with a warning that took me six months to find out about. Basically the warning states that if you put one foot of line with this battery then you are going to find out all about death!

 

[Sean9002]

with no load gets 96.3mph - still to test on road

FAAAARRRK!

Well will update this tomorrow with rest of build details, picture and video!
BIke

Looking forward to seeing this thing!

 

[Psycholist666]

UPDATE
OK so time for honesty, this project failed miserably!

Lack of knowledge = Failure!

First thing that went wrong on the test rude was the rear suspension collapsed as it was set up for an 80 Kg rider not a 120 Kg rider plus 30 Kg of drive components.
Second was that the clamp to the frame from the drive system was inadequate so the drive system rotated outwards on the frame.

I was still going to upload pictures as a reference on how NOT to build a power bike but I feel that both myself and my colleague who has funded this project are to blame and the pictures will show components made by other members and it's not the fault of them or the designs that contributed to the faults that this bike had.

So onwards we go. The bike is now being built on a Downhill MTB that has a square tube frame, the drive will be mounted on a much firmer and solid clamp and the frame geometry gives us the opportunity to hide some of the components like the Ice 2 HV160 controller and the huge shunt. The build so far is going well but taking it's time. I don't have access to a CNC Mill so all the clamp etc is being hand made and this has been hard especially working in an unheated Garage with cold metals that make your fingers go numb in minutes!

The original bike was to be a two motor drive but we had problems getting these to run synchronously and I feel that it was may down to lack of knowledge but the main factor may well have been that we are running the CA3 from an external 0.50 mohm shunt which only ran off one side of the motor wiring system and it was may be the case that if you are going to run a 2 motors in parallel format that you would need to put a shunt on each side of the configuration to keep the resistance from the wiring loom equal. I would appreciate comments here as I may have another go with the 2 motor configuration.

I also need to find someone to try and repair a an CC Phoenix Ice 2 HV 160 controller. I have opened this one up and had a look for the obvious signs of damage but can't see anything wrong. It may have been blown by a back current when the drive system went cap-put. All I know is that it doesn't work, can't communicate with it via the Castle Link and it won't fire up as the LED just flashes red. Anyone in the UK who can do this?

 

[Lebowski]

[youtube]WwlNPhn64TA[/youtube]

 

[ferret]

You can send the controller to Castle for repair or replacement.

Avner.

 

[AussieJester]

yes send it back for paid warranty to Castle, done this to many times with CC160s

KiM