Building a new Ebike

[snellemin]

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.

[RC-Monster Mike]

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).

[snellemin]

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

[snellemin]

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.



sensored






sensorless

[snellemin]

Got me some oldies Hope Brakes and MRP chainguides. Still waiting on my Hydraulic pressure switches for the brake cutoff.

[snellemin]

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.


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.

[snellemin]

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.

[RC-Monster Mike]

sweet bike!

[snellemin]

Thanks Mike.

[snellemin]

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.

[MonsterMaxx]

How much does it weigh?

[snellemin]

Originally Posted by MonsterMaxx

How much does it weigh?

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

[snellemin]

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_qR90MVioo7t_pn9i3hQ&index=1[/YOUTUBE]

[YOUTUBE]watch?v=nbkwbLBFWp4&feature=share&list=UUA1_qR90MVioo7t_pn9i3hQ[/YOUTUBE]

[snellemin]

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.






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.

[snellemin]

[YOUTUBE]watch?v=y7nkQ9Azc70&feature=share&list=UUA1_qR90MVioo7t_pn9i3hQ[/YOUTUBE]