Building a new Ebike

[RC-Monster Mike]

The 140 moto frame kit is quite appealing to me - I am just not in love with the hub motor setup, though I haven't tried one personally. It sure is a nice looking setup and would bridge the gap nicely between my dirt bikes and mountain bikes though.

[snellemin]

Went riding the Raptor a bit today. Was hard on throttle most of the time.

75.6C Controller, heatsinked to chassis. After 10 minutes of rest, case temp dropped to 55C.
67.2V, 10.8A used @ 18.4 miles.
49.4 Wh/mi, 7773.8Wh.
4.1% Regen.
Motor at 143F.
91.52 Amax, 65V min, -22.9 Amin.
54mph Max. Max throttle set at 115%.
Battery 101F max.

[snellemin]

I'm not a fan of the Qulbix name, so I got a new sticker made. Emonster!

[snellemin]

So I went back to the 203mm rotors. I'll be changing the front caliper to Marta FR one of these days, which is slightly bigger and uses the same brake pads. I used my poor man machining skills and trimmed up the rear brake caliper by a few millimeters. It fits nicely after some filing and sanding. Now I can clear the rotor with the 5 speed freewheel installed.

[snellemin]

Finally got around to installing one of my fav bike lights. Runs off 2s4p samsungs 18650's.

[snellemin]

Reprogrammed the controller to 200A phase and 91A battery current. Tweaked the throttle setting in the CA and now have a nice smooth powerful setup that rides very nice on the streets. CA recorded a peak of 99.7A @ 69.4V.

[RC-Monster Mike]

Sounds pretty peppy!

[snellemin]

It is Mike. 40Mph comes in a hurry. Going from 30->40mph is very responsive, yet smooth. Cruising around at 48mph is no problem. I have around 1Kwh of battery capacity and that is plenty for me right now. I still have some space inside the bike for another 18s3p 5000mah battery block.
My next upgrade could be a sine wave controller from sabvoton. With that upgrade, I would need to go to 19" moto rear rim and tire to stay safe on and off-road.

[snellemin]

Here is build list of another forum member on Endless-sphere. He goes by the name of offroader.


His total build price was around $5,678 USD.

Torque Raptor Motorcycle Frame kit = $1,528
24 packs of hobby king Turnigy 6s 20C 5000 MAH = $43 x 24 = $1032
2013 Marzocchi 888 RC3 Evo V.2 Fork = $757
Shimano 640 zee rear brakes = $130
Shimano 640 zee front brakes = $130
Shimano XT RT-86 Rotor Front = $40
Shimano SM-RT66 Rotor Rear = $29
Truvativ Hussefelt Riserbar 40mm rise = $40
Dicta BMX Freewheel 16T 3/32" = $11
Shimano MX80 Pedals = $60
Shimano M645 Zee Crank, 165mm, 83mm, = $119
Truvativ Hussefelt Stem, = $24
Cromotor v3 = $595
FOX 2013 DHX RC4 10.5 x 3.5 = $340
Lyen 18 FET 4110 MARK II controller w/options = $250
DMR Convertable Front 20mm disk Hub 36h = $57
Cane Creek 40ZS44 Short Cover Headset = $43
MTX 39 Rim = $50
Duro Razorback 26" Tire = $28
Maxxis Schrader DH Tube 26"x2.5"-2.7" = $15
14/15 gauge spokes w/nipples front = $36
Prowheel 19x1.4-TTRBKR = $79
Bikemaster Tube 2.75/3.00 19 = $12
Shinko SR241 2.75-19 = $31
11/12 gauge sapim spokes w/nipples rear = $72
Cycle Analyst CA3-DP = $150
ODI Ruffian MX lock on grips = $20

[snellemin]

I rearrange the battery setup and cleaned up the wiring. I'm happy with the headlight, so I'll make that to a permanent setup and soon wire it up the main battery pack.
I did get to fit a 42T chain ring with space to spare. I had to add a spacer to the chain guide and remove the chain ring guard.




Powerlab 8 hard at work

[snellemin]

Got me some Tektro E-sub brakes. The calipers look well made, but these have small brake pads. The brake levers look like quality stuff. Maybe swap over to TRP 4 piston calipers with the brake levers. For now they'll sit in the "to do" box.






I'm pretty good at setting up brakes, but for the life of me, couldn't stop the brake brake squeal on the rear. I got tired of fighting with and just bought me this Hayes tool. After 2 minutes with this tool, I had quiet brakes again.

[snellemin]

So instead of going with the moto rear wheel, I swapped over to my old Michelin's tires that was on my EVG bike. Big difference in how much better they ride vs the Crazy Bob's. Less rolling resistance, hang lower in corners, I can power out of corners without fear and a little wider contact patch on the rear tire. The rear is 66 mm at its widest and 42 psi inflated. It's a bit lower pressure compared to the Crazy Bob's. I've decided to keep the Raptor on the streets for a while and just run my mid drive on the trails.

[snellemin]

This is from my ride into work. I'm not missing the 21s lipo setup at all. 18s still has plenty of speed and acceleration.

[snellemin]

I installed my old 300lbs Titanium spring. Bike rides lower and can lean a bit lower in turns. Nice and comfy on the road and the Michelin's roll smoother vs the Crazy Bob's.

Vid of me climbing some steps after Critical Mass.

[youtube]OgKpPlz028M[/youtube]

[snellemin]

I relocated the controller to the topside on the inside of the battery box. This way I can lay down all the batteries. Well it worked for a bit and controller died on me. I'm sending the ESC in for repair and in the meantime hooked up a sensorless controller. I'm not too happy with it, so have decided to hook up a Sabvoton controller instead. Hopefully I can figure out the wiring and not so user friendly program app.