BE-Bike - The project starts NOW - Turnigy 130KV Brushless
 

Hi Guys!

A few months ago I made a topic at endless-sphere about converting my mountainbike to electric, I got very helpful reply's from members of this forum (thank you! especially: Aussiejester, Thud and sona1111). Today I turned 17, and I finally bought some stuff at Hobbycity for my MTB. (I actually bought a present for myself lol) The MTB I'll convert is a little old and rusty, but I think it will be OK. Some old pics of this rusty thing (I'll disassemble all the parts, clean etc. them and then re-build the bike before I'll convert it):

http://i424.photobucket.com/albums/p...t/IMG_1806.jpg
http://i424.photobucket.com/albums/p...t/IMG_1813.jpg

Now to the things I just bought at Hobbycity (a total of $480 :o ):
- Turnigy 80-100-B 130Kv Brushless Outrunner (I know, overkill :intello:)
- 2* ZIPPY Flightmax 5000mAh 5S1P 30C
- iCharger 3010B 1000W 10s Balance/Charger :oh: I'm very curious about how this thing will perform, at this moment I've got a cheapo 50Watt charger :lol:
- Turnigy Servo tester
- Turnigy HV UBEC (8-42V)
- Some small things like connectors, ball bearings, thread locker and some other things for my RC's



Things I still have to buy:
- Castle Creations ICE HV 120A ESC
- Gears, shafts, aluminium, caps etc.



I'll only use 2* 5Ah 5S 30C LiPo's in series, but gear the bike down to about 35MPH to get the current down. As reduction unit I'll try to make something like Mud2005 at Endless has:
http://www.endless-sphere.com/forums...e.php?id=31041, a belt driven system from motor to a shaft, then a chain driven system on the other side of the shaft.
3 questions about this:
- Where to get a hardened shaft?
- Where to get the 'belt drive system'; a small 12mm inside dia. gear, a big gear and a belt? (Sorry my English isn't that good, I don't know the name of the parts)
- Where to get a freewheel + sprocket that will fit the hardened shaft?
I'm still not sure how the sprocket/freewheel on the shaft will drive the rest of the bike as I want to be able to paddle too.



I'll keep you guys updated... :)


Oh, and for you who want to know why I'm calling it the BE-Bike: as you see I bought the first things on my birthday, so it's a Birthday Electric Bike :lol: I know that doesn't makes sense lol

Now I'll enjoy the last 4 minutes of my birthday hehe (It's 23:56 over here)

What power supply are you going to use for the 3010B iCharger? I am interested in getting that model myself, but my current power supply definitely would need to be upgraded too.

No disk brakes, this is an outrage.



Just Kidding, this is a stellar project, one that I wish to perform in the future.

I'll only use a 12V 500Watt PC power supply (I got it today, I have to convert it), as 500Watt is enough for the coming years. Maybe I'll get a 1000+W power supply in the future, but for now it is not necessary.


:lol: Maybe I'll buy some in the future (these things are very expensive imo), but for now I'll keep the normal brakes.

pc power supplys are rated with all channels driven, the 12v rail is only a portion of the 500watts

Jup. My power supply is 800Watt and the 12v rail is idd 500Watt.

No way, first he finishes the LST 1.5 and now he's starting the e-bike which he has been jabbering about for so long and spends a ton of cash, I like the new you :D

Again on here: Happy B-Day!

Ooh lala, this should be funy.
Dang, a $400 birthday present?
:surprised:

Any progress on this build?

Metal! You actually were my first inspiration for this E-Bike :intello:


There isn't much progress, I ordered a bunch of things but I haven't got anything yet. Only one item (the LiPo's) has to get in stock at Hobbycity before the whole order gets shipped, hopefully it won't take too long. I also ordered a ENO freewheel ($80), an adapter from a member of Endless-Sphere ($20) and some caps ($10) for the ESC.

I've decided to go with a Castle Creations ICE HV 160. I want to buy it at Towerhobbies as I get a nice discount over there but they have only got the Lite version. I e-mailed them yesterday if they get the normal one in stock, no answer yet...

Awesome! I have almost 600mi on my bike now and I'm getting to really dislike the hub setup. This fall/winter I want to get a new bike, re-use the controller/batteries but use an outrunner. The hub motor is really heavy and it doesn't agree with the gravel roads I ride on. :smile:

You have a really nice bike to build off of! I'll be keeping watch on this thread!

This is a cool project. One of the guys has a converted mtn. bike at my LHS. He was saying he has something like 600mi on it, using a hub style motor. He has been having problems with broken spokes. I'm not sure if that is poor maintainence though.

I have a line on a Honda Rucus scooter with a bad motor for a BL project. We'll have to see it that pans out though. I'll be watching this.

-JB

Do you two know each other? :lol:

Update!


Today I FINALLY (it took 1,5 month....) got my HC package! Some pics of the items from the HC package and some other ones I got a few days before:

http://i424.photobucket.com/albums/p...t/IMG_2940.jpg
ENO 16T Freewheel


http://i424.photobucket.com/albums/p...t/IMG_2942.jpg
Paint! Correct: the bike will be Black, Green and Pink! :intello:


http://i424.photobucket.com/albums/p...t/IMG_3026.jpg
Adapter for the ENO freewheel with 1/2" bore


http://i424.photobucket.com/albums/p...t/IMG_3024.jpg
The awesome package that came today from HC! 1000Watt charger, 2* 5S LiPo's, 8mm Bullet connectors, UBEC, Servo tester and the...... MEGAHUGEMEGAMONSTER Motor! This motor is sooooooooooooooo huge, big and heavy! Totally awesome!


http://i424.photobucket.com/albums/p...t/IMG_3025.jpg
My sexy hand + XXXXXL motor


http://i424.photobucket.com/albums/p...t/IMG_3027.jpg
My Rustler and the XXXXXXXL motor!


http://i424.photobucket.com/albums/p...t/IMG_3028.jpg
Some other brushless motors and again the XXXL motor

Awesome! Can't wait to see it come together!

I am a little worried about your range.. My 666wh pack get me 15-25mi, and you have a 185wh pack.. I'd guesstimate you'll only get about 4mi (6km) when riding hard and probably 7mi (11km) when taking it easy and pedaling..

I've ordered another 2* 5S LiPo's at HC a few weeks ago. This package is at the customs right now and I've got some serious trouble with them I think, so it could take some time till I get those. I'll wire them as 10S2P ofcourse. So I got a 370Wh pack instead of a 185Wh pack. I'm very curious about how the range will be, if I get 12km I would be very happy :yes:

I bet you'll get 12km easy with four 5s packs. That motor on 10s lipo should sip a lot less power than my overvolted hub motor.. My motor is rated for 1000w and I am running 4.7kw. :lol:

BTW yesterday I made a video. You can use it as motivation. :smile:

12km would be very nice!

Hehehe! That vid is awesome! :intello: And that bike is damn fast too! 42MPH :surprised: (Mine will be geared for 35MPH, but hopefully a LOT of wheelies lol)

Subscribed
I wanna see that Giant Turnigy in action.

Nice! I want to see this motor in action too... :yes: I got a dirt skateboard with a busted motor mount waiting for one of these. :lol:

@ Metallover, that's one fast bike .. sjee

@ Byte, we'll have to make a sweet vid of that e-bike monster of you. We can also use it to film our RC's, you know you filming and e-biking and than RC's come flying by!!

:gasp::surprised: Thats crazy. No way I would have the balls to go that fast on two skinny wheels like that and no leathers for protection. Maybe I gotten a bit soft in the old age. Anyway I really liked the bit when you were traveling up the hill at around 40mph and pedaling, pretending that you were doing the work. :rofl: Funny as all heck. Burnout on the grass was pretty cool too.

Update...


I painted the bike last week. As I already posted before: black, green and pink ghehe

http://i424.photobucket.com/albums/p...t/IMG_3049.jpg

http://i424.photobucket.com/albums/p...t/IMG_3051.jpg

http://i424.photobucket.com/albums/p...t/IMG_3053.jpg

http://i424.photobucket.com/albums/p...t/IMG_3054.jpg

http://i424.photobucket.com/albums/p...t/IMG_3055.jpg


It should look like this if the first 2 parts are mounted to each other:
http://i424.photobucket.com/albums/p...t/IMG_3064.jpg



I think most people will find these colors gay and stupid, but as this is a BIRTHDAY E-Bike it suits well imo :intello:

Looks great except where you sneezed on it ? JK

Certainly looks a bit different, I like it for originality. I'm sure once it's built/assembled the colors will tame down a bit.

Hehe :lol:

I will try to assemble the bike next week and measure some things. I forgot to add the drawing I made in SketchUp for the motormount a few weeks ago. I didn't draw the sprockets, but there will be a 14T sprocket on the motor, 72T on the 1/2" shaft and the 16T ENO freewheel will be mounted on the other side of the shaft. These parts will be CNC'ed as I'm too lazy to make them myself like I did on my LST 1.5 :tongue:

http://img827.imageshack.us/img827/8546/49196677.png

http://img842.imageshack.us/img842/804/61945203.png

I won't lie...
I actually am digging the abstract theme.
I've always had a thing for abstract stuff, wallpapers, paintjobs, etc.

Good job!

And shame on you for using Windows Live Messenger! :no:

:lol:

You should definitely check out Deviantart if you don't already know it, they got LOTS LOTS LOTS of photo, wallpaper etc. stuff.

Lol! You guys in America use AIM, aren't you? Well, over here in the Netherlands 99% of the people don't even know what AIM is hehe... Windows Live Messenger works fine for me :na:


I'm going to bed now, it's 2:13AM and I'm very tired... Goodnight! :)

thats quite a project I couldnt believe even Best Buy is trying to get in on the action selling 1300 to 2500 dollar ebikes on the floor next to TVs

Whoa, Best Buy is now selling ebikes?
Hehe, this should be pretty funny!

And yup! Most of us "fat" Americans use AIM :D

And yes, DeviantArt...
Love it!

Got my CC ICE HV 160 and Astro Flight servo tester in a few minutes ago. I will solder some 8mm bullets on it tonight and also the 2200uF 63V caps. The ESC is way smaller than I thought it would be.

http://i424.photobucket.com/albums/p...t/IMG_3157.jpg

I also got 16 meters(!) of white braided sleeving and 5 meters of white heatshrink. I'm still waiting on the Magura throttle I bought 2 weeks ago...

Waiting for the motor action.

keep us posted!!! Looks good!!! i want to do something similar!

Hi!

I got some parts in:
- Magura Throttle
- Astroflight servo tester
- Sickbikeparts cranks, freewheel and sprockets

I soldered a lot of stuff last weeks, today I made a movie of the motor running, nothing spectacular:
Click!

As you can see; the first 1/3 part of applying throttle the motor stays in neutral, I still have to fix that.

Sickbikeparts:
http://i424.photobucket.com/albums/p...t/IMG_3168.jpg

WOW, never seen 10S plugged in before....

Hehe, since I soldered on the extra 3 2200uF 63V caps there appears a big spark and a funny "boom". It shocks me everytime lol

yeah, haha. Saw ya jump a bit ;)

Very nice. Have seen a few out of the ordinary projects with these turnigy motors now.

Might have to do ome myself one day....

Looking forward to seeing more progress.

Oh by the way nice paint job. I done a similar job on a old bmx i had when i was about 16.

Little update:

I opened up the Magura throttle... long story short: I twisted the pot a few times till the wires broke off :oops: (I was thinking like "heh? why can I turn this pot so far?" And a few secs later the pot was loosened from the wires hehe :whistle:) I'll fix that soon.
http://i424.photobucket.com/albums/p...t/IMG_3170.jpg


I received my order from SDP:
- #25 Pitch 3 foot chain
- 0.5" Dia. 5.5" Length Stainless steel shaft
- #25 72 teeth spur
- #25 14 teeth pinion
- #25 connecting link
And I also ordered 2 ball bearings at eBay.
$140,-
http://i424.photobucket.com/albums/p...t/IMG_3177.jpg


I also got a new workspace, my grandparents offered this to me. It's not big, but I love it. I also received the cross table you can see in the second picture, it's a heavy thing. Costed me about $130,-
http://i424.photobucket.com/albums/p...t/IMG_3174.jpg
http://i424.photobucket.com/albums/p...t/IMG_3175.jpg

And I received my 7075 aluminium, all pieces are 12mm thick. This stuff was expensive: $80,-
http://i424.photobucket.com/albums/p...t/IMG_3176.jpg


I will start working on the aluminium in a week (I'm busy now).


- Patrick


EDIT: Oh yes.. I ordered 2 pieces of plexiglass. One is just regular white transparant and the other one some kind of black color.

Waiting on updates bro ;)

after 2 months finally a update! After LOTS of hours of measuring, drilling, dremeling, filing and so on I came to this result. The aluminium 7075 is really strong stuff by the way! It's not finished yet, I need to make 3 pipes from aluminium to secure both pieces of alu with the 3 screws you can see. Also I need to drill out the bore of the small sprocket so it will fit the 12mm motorshaft and ofcourse I need to make something so that it can be mounted on the bike. (But I'm very busy with school, so it could take a while till I get that done)

Both pieces
http://www.imgdumper.nl/uploads4/4d9...9-IMG_3198.JPG

If you look closely you can see that I left just a little aluminium in the big hole so the bearing won't slip away.
http://www.imgdumper.nl/uploads4/4d9...c-IMG_3200.JPG

Fitted bearings and mounted the motor
http://www.imgdumper.nl/uploads4/4d9...8-IMG_3197.JPG

Complete drive unit front side
http://www.imgdumper.nl/uploads4/4d9...6-IMG_3194.JPG

Complete drive unit back side
http://www.imgdumper.nl/uploads4/4d9...e-IMG_3196.JPG

Complete drive unit up side
http://www.imgdumper.nl/uploads4/4d9...9-IMG_3195.JPG


- Patrick