GNG Bike - Norco Six / Giant Team DH

E-Norco · Apr 24, 2013

Hello Endless-spheere members.
This is my first post in this great forum.
After reading days and weeks i decided to build my own electric freeride Bike.
At first i choosed the bike to convert:
Norco Six One

Then i was waiting for the Postman

...change drive to Deore 9Speed steel casette and KMC X9-E Bike chain

...installed the kit, smoothed the motor pinion and replaced the chain tensioner with old Roox Rollercoster
1st problem- a lot of space between clamp holder and downtube

...problem solved...

...stored the controller in a cheap ebay bag...

View attachment 5

...tuned the throttle grip to thumb throttle...

...built protective cover for the belt drive...

...power is delivered by four Turnigy 6s 5000mah lipos, charger is a Revoelectrix Cellpro Powerlab 8 and the charger supply is built of two 800w server power supplys in series...

View attachment 3

I am using backpack battery and the first testrides was a lot of fun.

...today i tried the shunt mod with 1mm wire-amazing torque increase

Until now the belt looks good but the cranks and the bottom bracket bent after the first freeride test.
So I ordered a 165mm bmx crank axle http://www.bike-mailorder.de/Bike-T...komplett/Gusset-Pigmy-OKR-Achse-fuer-MTB.html
and the matching bottom bracket http://www.chainreactioncycles.com/Models.aspx?ModelID=95508 to use the Profile BMX cranks from my Dirtbike.
At the weekend i want to build the freewheeladaptor for this setup. I hope it will work until next week.

spinningmagnets · Apr 24, 2013

There are a dozen ways to build a cover, and this one is very nice. Could you add more details and pics of that build (if you have them). I think a lot of GNG-builders would like to make something similar.

Whiplash · Apr 24, 2013

Yeah nice build have fun!

bart1006 · Apr 24, 2013

Nice build!!

farmkid4 · Apr 25, 2013

Very nice!

When you get the new bb could post more on the install and how it works?

skyungjae · Apr 25, 2013

http://endless-sphere.com/forums/viewtopic.php?f=28&t=47618&start=75#p713625

Maybe this will work for your incoming crank arms.

christerljung · Apr 25, 2013

Nice build! How is the rearsuspension reacting at accelleration on this frame? Does it "sink"?
That beefy BMX BB-shaft looks good. Maybe an even better upgrade than the cyclone ISIS? It looks like it will be possible to add a support bearing on the inside of the freewheel.
Be prepared for #25 chainconversion, a lovely troubelfree upgrade.

skyungjae · Apr 25, 2013

christerljung said:
Nice build! How is the rearsuspension reacting at accelleration on this frame? Does it "sink"?
That beefy BMX BB-shaft looks good. Maybe an even better upgrade than the cyclone ISIS? It looks like it will be possible to add a support bearing on the inside of the freewheel.
Be prepared for #25 chainconversion, a lovely troubelfree upgrade.

Every time someone mentions that #25 chain drive... makes me want to do it too. :x

E-Norco · Apr 25, 2013

skyungjae said:
http://endless-sphere.com/forums/viewtopic.php?f=28&t=47618&start=75#p713625

Maybe this will work for your incoming crank arms.

I think for this adaptor you need an axle wich is minimum 180mm wide.

E-Norco · Apr 25, 2013

spinningmagnets said:
There are a dozen ways to build a cover, and this one is very nice. Could you add more details and pics of that build (if you have them). I think a lot of GNG-builders would like to make something similar.

I will post detailed pictues soon when i disassemle everything for crank upgrade.

E-Norco · Apr 25, 2013

christerljung said:
Nice build! How is the rearsuspension reacting at accelleration on this frame? Does it "sink"?
That beefy BMX BB-shaft looks good. Maybe an even better upgrade than the cyclone ISIS? It looks like it will be possible to add a support bearing on the inside of the freewheel.
Be prepared for #25 chainconversion, a lovely troubelfree upgrade.

The frame has a Specialized rear triangle. The "sinking" should be similar to your Big Hit -noticeable...
I have got two spare belts in stock. If they are broken i need chainconversion!

E-Norco · Apr 25, 2013

Crank upgrade update:

Today I built a adapter set to fit the left side of an BSA-BB to my setup.

View attachment 4

plugged together:

Tomorrow i weld it together.

The distance between the cranks is about 165mm. I hope it fits.

I also bought a new bearing 20x32x7mm to replace the support bearing.

Now I am still waiting for my new Euro-BB...

E-Norco · Apr 26, 2013

Update:

Adaptor ready to install:

View attachment 2

E-Norco · Apr 27, 2013

Second bearing fitted:

space between cranks and kit:

Final prduct Profile Racing Freewheel Crank

...still waiting for the BB

spinningmagnets · Apr 27, 2013

Do you have a source for this adapter? The only online source I could find has stopped making them due to low sales.

E-Norco · Apr 27, 2013

spinningmagnets said:
Do you have a source for this adapter? The only online source I could find has stopped making them due to low sales.

This adapter is made by myself.

skyungjae · Apr 27, 2013

What gauge wire are you using from your battery pack to the controller?

E-Norco · Apr 27, 2013

I am using 12AWG silicone wire with 4mm bullet connectors with sleeving.

skyungjae · Apr 27, 2013

With your 1mm shunt mod, what are your peak amps?

Sorry, I should've asked this with my wire question. :wink:

justlooking · Apr 28, 2013

watching this thread ,,

E-Norco · Apr 30, 2013

Hello,
today the bottom bracket arrived and everything fits together.

After about 1.5 hours testride someting is broken

. I think it's the controller which is become a little too warm.
So 1mm wire shunt upgrade is not recommended. Now i need a new one.9FET Lyen Controller?
Or what do you think what it could be?
If i plug in the battery and want to accelerate nothing happens. How can i messure which parts are in function?
Thank's for help.

justlooking · Apr 30, 2013

first thing to check ,, this have given trouble with mine and some others had the same trouble ,,
the plastic yellow block connector ,, get rid of it ,, then see if it works ..

skyungjae · Apr 30, 2013

justlooking said:
first thing to check ,, this have given trouble with mine and some others had the same trouble ,,
the plastic yellow block connector ,, get rid of it ,, then see if it works ..

It's very easy for the connections inside to rattle loose. I used Anderson Powerpoles from the get go.

I was thinking about using a piece of paper clip for the shunt mod, but your predicament makes me reluctant on doing so. Perhaps I should find a T-50 staple.

What were your Amps peaking at with your 1mm wire shunt mod?

E-Norco · Apr 30, 2013

It's very easy for the connections inside to rattle loose. I used Anderson Powerpoles from the get go.

I was thinking about using a piece of paper clip for the shunt mod, but your predicament makes me reluctant on doing so. Perhaps I should find a T-50 staple.

What were your Amps peaking at with your 1mm wire shunt mod?

I will remove the box tomorrow and see what happens.
So far I have not measured the amps because the power meter is not there yet.
I think it was a bit to much.

christerljung · May 8, 2013

Have you got it running again?
I'm trying to find parts for the shaft you linked previously, to build a bulletproof freewheeling crank with supportbearing:
http://www.bike-mailorder.de/Bike-Teile/Innenlager/Innenlager-komplett/Gusset-Pigmy-OKR-Achse-fuer-MTB.html
Really hard to find affordable crankarms with 36 spline. I've only found these so far:
http://www.ebay.com/itm/Pigmy-2-165mm-Crank-Arms-Japan-Butted-SAE4130-Tubular-Cr-Mo-for-19mm-36-Spline-/110935243398?pt=UK_sportsleisure_cycling_bikeparts_SR&hash=item19d4417a86
70£ hmmm.

GNG Bike - Norco Six / Giant Team DH

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