Building a new Ebike
 

Hey Guys. Been a while since I've posted anything. I've moved to a new "old" house. So I haven't been able to play with any of my RC toys at all. Fixing up the new place does take time away to do much of anything else. But I did start up a new ebike build that is taking a while to finish.

The ebike frame came from Slovenia and took 1 month from fabrication to delivery at my door. The motor is a Greyborg beast and got that through the USA distributor. I purchased two 18 Fet controllers and I'll have to see which I like best on this heavy frame. Anyways, I got both a sensored and sensorless controller. The Cycle Analyst is the latest version and has plenty to mess around with. Batteries will be my same old Sky lipo 6s packs and a pair of 3s Gensace. Sometime next year, I'll get me a A123 pack build.

So this is what I received in one box.
http://i189.photobucket.com/albums/z...r/DSC09208.jpg
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I installed a 26 x 2.3 tire on the 46mm rim. I had requested the dropout to support a Cromotor and 5 speed freewheel, thus 165mm dropout spacing. Well it looks like I'll go with a 3 speed or two speed freewheel instead. Too bad a Schlumpf drive can't/won't fit.

I am disappointed in one thing. For the money I have spend on this frame, I expected a non-tweaked chainstay to get too the 165mm dropout.
I've emailed the company and they agreed to send me a new swing arm on an open forum and email. Lets see if they do send me a new one.

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Got me a DNM fork that is dual disk capable. The dude at Bike Barn laced up the hub for me into a wheel.
http://i189.photobucket.com/albums/z...r/DSC09211.jpg

Here's Zombies 18Fet controller. This is when I want to play with regen at 24s. But for real running on 24S, I will need a bigger controller for the Cromotor.

http://i189.photobucket.com/albums/z...r/DSC09234.jpg

This is the Hygia E-hydro brakes I got through Greyborgusa. Uses a hall sensor that is screwed on the bottom of the brake handle.

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I have a pair of V3 CA's. One for Lyen 18fet sensorless controller and one for Zombies 18Fet.

http://i189.photobucket.com/albums/z...r/DSC09236.jpg

Got the 50 dollar 9.5" shock from Ebay. Looks ok for the price and fits nicely.

http://i189.photobucket.com/albums/z...r/DSC09260.jpg


Got me some stuff from evworkslab.
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Used a spacer on the fork before installing the Cane Creek headset.

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Getting there...The bike is tall or I'm just too damn short. Waiting on more stuff to arrive next week.


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Installed an old set of 165mm cranks. Still need to look for a new rear brake, as the the one I have is leaking oil. The front brake lines are find, but need to install some spacers between the brake rotors.

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This is my Bike Barn :oops:
http://i189.photobucket.com/albums/z...ps3affcf97.jpg

Very very nice :)

My thoughts exactly.

I agree looks like a nice build.

I love it. Wish I had a need/excuse to build an e-bike.

Radical
 

The frame looks pretty radical for a bicycle. Looks more like a motocross frame. Very nice setup, but with the weight I am surprized that you are not going with front and rear motors to give yourself more torque and easier hill climing. That would help to keep the stress and heat lower on anyone motor or controller.

Those Greyborg bikes are cool - as are the Stealth EBikes. Both are not inexpensive, though. I am looking forward to seeing this thing built out. :)

The motor should be able to handle the weight. After all it's a 5 times more capable vs my Magic Pie motor. I do have another seat mount that attaches to the frame. It takes a 30.9mm seat post and I have a sleeve coming in so I can use my current 27.2mm seat post. With the right(more expensive) esc, you can push 70+mph with that motor.

I really wanted the Greyborg setup in the beginning, but this frame looks meaner and was available at the time. The Greyp bike is a nicer setup with the new side panels.

Just built you a cheapy one like I did in the beginning. R&D should be a good excuse.

Thanks homies!

http://acidcow.com/pics/20111123/com...e_faces_19.jpg

Looks super pimp, snell'. I feel a bit like brainanator, seeing something like this makes me want one. Not gonna happen though.:no:

Yup, it's around 71mph / 113kph with 127A @ 125V on level ground with my size tire. But, my pockets are not deep, so I opted for a 40mph esc setup.

So I'm still up in the air between a sensored and sensorless setup. There is a newer esc out that can do both, but it won't be big enough for my needs.
I"ve decided that the Cycle Analyst will control my throttle and brakes. Regenative braking will still be handled by the esc itself. The Cycle Analyst will give me the ability to set up a variable power level. So for just riding in the streets I would like a max of 1500W and for offroading zero limit. Or I could wire up a switch and have 3 different power levels programmed. I will need to cut up the frame a bit to make the Cycle Analyst fit and figure out the wiring.

70mph is haulin' on a bicycle! I prefer torque over speed, though(I am more of an off road type, and not a flyweight, either). I gotta build me an ebike one day(I do have 2 e-bikes now, but neither have peddles and only one resembles a bicycle somewhat).

70mph on two wheels is way too much for me. 30mph on a single track, zooming between the trees is scary at times. This cromotor is capable of 5000W all day long and 12KW burst. Now take this same motor and stuff it in a middrive setup for insane RC-Monster Torque.
The Cycle Analyst does have torque throttle feature, which I will try out for off road duties.

So I love torque too, hence my love for dragracing anything with uber torque. But didn't like the direct drive setup on my 42" wheel base Fuji bike. Weight distribution just sucked and zero lowend torque. So on the same bike I setup a mid-drive unit and it's a day and nite difference. Weight is all in the low center. Throwing the bike into corners is way better. Instant low end torque and only use 15s1p 5Ah lipo pack. Power consumption is about the same as the direct drive setup, when riding the same trails.
The first reduction stage is a belt drive and I push a peak of 37.5A through it. I could push 50A through the setup if I were to swap the belt drive to a chain drive. But that would be a bit much for where I ride.

Here are pics of the mid drive bike

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I know some of you appreciate nude shots.

18fet ebike ESC's. One is sensored with 125V capable fets and the other is sensorless 100V max.

http://i189.photobucket.com/albums/z...psc7dd63a2.jpg

sensored
http://i189.photobucket.com/albums/z...ps16a2747e.jpg
http://i189.photobucket.com/albums/z...pscbfe594f.jpg




sensorless
http://i189.photobucket.com/albums/z...ps70aa507d.jpg
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Got me some oldies Hope Brakes and MRP chainguides. Still waiting on my Hydraulic pressure switches for the brake cutoff.

http://i189.photobucket.com/albums/z...ps5a16c402.jpg

So some updates:

The frame manufacturer did send me a new swing arm. They shipped it free of charge and it wasn't cheap for them to do so. The new swing arm looks a lot better and the shock mount is tweaked a bit to allow a larger diameter tire.
The new swing arm is on the left.
http://i189.photobucket.com/albums/z...r/DSC00253.jpg

The dual disc brakes didn't work out. They leaked at the pistons and I'll have to fix them later on. In the meantime I found some Julie Magura ebike brakes. These have the brake cutoff sensors build inline with the hydraulic lines. These work good at slower speeds, but I'll have to depend on regen braking at higher speeds. I still need to wire it up for that.
http://i189.photobucket.com/albums/z...E782C8E259.jpg
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I almost finished the bike. Still to clean up the install, wire up the brake cutoff and mess around with the CA.

The test ride was nuts!! Cromotor is a beast. Torque is insane when I went offroading a bit and the 3 speed came in handy. The throttle control coming off the CA is pretty good. The bike handled nicely, but will get better once tweaked. Pedaling was a PITA with the bike seat in place. If the bracket was slimmer from the top, my legs would not hit it. I'm putting back the moto seat.

I decided the put the controller inside the bike to keep the mud off from it. Still have plenty of space for the batteries.

The cromotor is just super quiet with Zombies 18fet controller. Gonna have to ask him what his default settings are.



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sweet bike!

Thanks Mike.

I put the motor seat back on. Blew my sensored controller, so I stuck a spare sensorless 18 fet controller in there. Not as smooth, but a bit more powerful.

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How much does it weigh?

It's heavy @ 107 lbs. Can be much lighter with a smaller motor and less batteries.

Here are two vids. The first one shows how easy the 5000W bike is to handle in a strangers hand. In the second vid you can see me in 3:08.

[YOUTUBE]watch?v=SohEsy5X7N8&feature=share&list=UUA1_qR90MV ioo7t_pn9i3hQ&index=1[/YOUTUBE]

[YOUTUBE]watch?v=nbkwbLBFWp4&feature=share&list=UUA1_qR90MV ioo7t_pn9i3hQ[/YOUTUBE]

I added some more copper on the traces of Lyen 18 fet sensored controller as I did with the sensorless version. The controller is a bit better at the topend and climbing steep hills from a standstill. Sadly no video. I managed a speed of 46.8mph. Bike feels like it can go faster. I'll have to find out what that limit is one day.


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I had my friend and his daughter ride the Raptor too. They loved it. He is about 265lbs and the bike still pulled him like mad. His daughter is about 115lbs and the bike takes off like a bullet with her on it.

http://i189.photobucket.com/albums/z...r/DSC00671.jpg

[YOUTUBE]watch?v=y7nkQ9Azc70&feature=share&list=UUA1_qR90MV ioo7t_pn9i3hQ[/YOUTUBE]

I swapped over to Schwalbe Crazy bob tires for some onroad fun. Well I hit 53mp and the bike just felt stable. Regen brakes got a work out too.
Got me some bigger platform pedals too and they feel better with this big heavy bike.
I had to add a spacer to the front brake rotor for some more caliper clearance.

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Friends having fun with the bike in the backyard.

[YOUTUBE]watch?v=V_as9nfTEuo&feature=share&list=UUA1_qR90MV ioo7t_pn9i3hQ[/YOUTUBE]

I finally got around to hooking up the E-brake cutoff and got to try out the CA cruise control. I still need to hook up another switch so I can enable regen with the ebrakes when cruising in the streets.
The CA V3 cruise control is really easy to use. Move the throttle and the cruise control disables. Hit the brakes and it disables. I have mine set at 6 seconds.

I increased the phase current to 150 and the battery to 73A. That little bit made quite a difference in how the bike behaves. Torque went up and throttle is a bit more aggressive. Climbing power is better too. Time to mess with the throttle setting in the CA.

http://i189.photobucket.com/albums/z...EE70E197E8.jpg

Indeed - more current makes a huge difference in "seat of the pants" power. On my Blade(74v lipo bike), I have it turned down to 250 amps(from 300) - this is still very aggressive power in tight situations but without the current limit the bike wants to leave me off the back!

I think I would kill myself with 250A phase current. If I go with a smaller moto rear wheel, I could gain some more "torque" and not having to upgrade my controller. I just came back from a 13 mile fun ride. Motor was barely warm. Controller case temp peaked at 65C and averaged 45C. The thermal pad on the bottom of the controller to the chassis works good. The chassis was warm right underneath the controller.

250amps is a lot of power for sure - can yank the front end anytime. It eats tires pretty quickly, though! The Blade is bigger than a bicycle(though uses bike components) - makes it more manageable. The wheelbase, height, stance etc. are similar to a full size dirt bike, but with mountain bike wheels.
I would love to have an in-between bike like yours, though - having the ability to ride on bicycle paths without bother, along with the ability to get home with a dead battery is nice and opens up more riding opportunities.

It was suggested to me to get a Kelly controller and use 250A on my bike, because that is what the bike deserves:yes: . The Kelly's are big and I have no nice way of mounting the controller underneath the bike.
Mike, can't you fabricate a bottom bracket and add pedals to your Blade? You would have an instant monster mid drive Ebike without spending a lot of money.

I'm sure I could figure a way to add pedals, but that isn't in the plans - would rather have a bike like yours in addition to mine...not instead of, as I love the machine the way it is. :)

Mike, how about something like your blade and my raptor? Have you looked at the Motoped?