Kinni's E-bike questions and stuffs

[dogman]

Looks ok, just put some kind of protection inside the bag. Old political signs work good for preventing dings on the pouches.

[Kinni420]

I think new political signs are better from all the bullshit posted on them. thicker before the BS wears off

Ok todays work! got some connectors for the harnesses I need and a 40w soldering iron for better connections. still waiting on 4mm bullets and charger from EPbuddy.

changed the layout of the torque arm. Although the angle of pull is as much as 45 degrees off, the rotation of the axle will cause the second arm to press on the big nut and cause it to rotate upwards instead of backwards here. should be fine until i can get to the metal shop.:



I changed the position of the controller to below the frame for better air flow and space for the pack. created a drip loop in the rear wiring and created a cover for the motor connectors out of an old innertube.



The hanging wires here will be shortened and stuffed into the pack I'm getting. Will post pics when done.

[Kinni420]

I just wanted to mention, I just bought a 40w soldering iron and the difference from a 30 is amazing. Its like a flame-thrower compared to a lighter. My wicking was phneominal.

also just ordered that bag from above. will have it saturday.

[dogman]

Well, I like to collect signs the loser is slow to pick up after a primary. Winners pick theirs up fast. Removing the signs before the election is a crime, so I don't do that. You can buy coroplast for sale signs if you must. Around here, there's always old signs out in the weeds just off the road somewhere when you need some. Regular cardboard works fine too, but isn't damp proof.

[Kinni420]

ive been collecting the thin plastic that lines suitcases. should be enough.

Now that Im about ready to ride, what should I be watching for? at 18s1p for the moment. when should I shut down? 80% of Ah? (4000 mAh on the CA) or should I be watching for voltage?
I really dont want to screw things up on my first ride to work.

[jkbrigman]

ive been collecting the thin plastic that lines suitcases. should be enough.

Now that Im about ready to ride, what should I be watching for? at 18s1p for the moment. when should I shut down? 80% of Ah? (4000 mAh on the CA) or should I be watching for voltage?
I really dont want to screw things up on my first ride to work.

EXCELLENT question. I set my CA low voltage cutoff to 66v, because that's what I've heard is a good low voltage point for LiPo. I don't recall seeing a setting like that in the CA.

Kinni - your build is coming along beautifully. Once you have the bag for the wires and such, you're gonna be golden. I'm watching carefully to learn from you as my next build will be an upright and have much more in common with yours than what I'm doing right now....

So: LiPo is going in the bag in the main triangle? Do you have any plans to add lights, fenders or a rear rack?

JKB

[dogman]

There is not much energy left in the pack past 3.65v per cell. I think they stay balanced better if stopped by then, or even earlier.

That's resting voltage, that is. Enough space to go a bit lower under load. Don't set a lvc too high 3.5 would be the highest I'd want it. 63v. Then figure about 2v of sag at least. 60v sounds good to me. Happens that's my 72v controllers lvc anyway.

[Kinni420]

I plan to add fenders. A nice fatty motocross looking one in the front, maybe just a small one in the rear to avoid the constant rain showers we get here. I used to have a big ass fender for the front on my old hard tail....cant remember the make. but most bike fenders are geeky looking.

I'd really like to get another old schwinn cruiser and build one up into an e-bike. My Cooks (pics above) is too classic to modify. Me and my buddy last night were talking about how that bike has been through 9 countries and 35 states. Ill never change it.

[jkbrigman]

I plan to add fenders. A nice fatty motocross looking one in the front, maybe just a small one in the rear to avoid the constant rain showers we get here. I used to have a big ass fender for the front on my old hard tail....cant remember the make. but most bike fenders are geeky looking.

I'd really like to get another old schwinn cruiser and build one up into an e-bike. My Cooks (pics above) is too classic to modify. Me and my buddy last night were talking about how that bike has been through 9 countries and 35 states. Ill never change it.

True: fenders are geeky. I've ridden both with and without them, and I'd rather have 'em. The "commuter ethic" is slowly seeping into the bike shops around here, and it's about time.

YES, the Cooks IS too classic to modify! I saw on GIZMAG once a story about a fully self-contained motor wheel: motor, controller AND battery all the wheel, with a wireless controller soft-clamped to the handlebars. That's about the only ebike modding I can think of you'd want to do to the Cooks - something completely reversible that doesn't change the frame in any way at all.

I was scoping out cruiser bikes for modification at Wal-Mart a couple days ago. Lots of pretty good looking stuff, but lordy it's cheap. Those cheap cranks give me headaches. But I have lots of interest in modding-up just the simplest bike you can get - a single speed with maybe a coaster brake - into as dead-simple an ebike as you could make. Stealth would be nice, but not mandatory.

JKB

[dogman]

Fenders look like shit, but I have to have them on my commuting bikes. One day I noticed a dark spot ahead in the bike lane. I didn't realize till I rode through it how fresh that puddle of oil was. Soooo glad to have a front fender that day, goo all over the bike anyway, but at least my face stayed clean.

If you run a rear rack on your bike, rear fenders can be made from anything, and just attach to the frame and the bottom of the rack. I prefer a strip cut from closed cell foam fatigue mats, mostly since I found those on the roadside too.

[jkbrigman]

Fenders look like shit, but I have to have them on my commuting bikes. One day I noticed a dark spot ahead in the bike lane. I didn't realize till I rode through it how fresh that puddle of oil was. Soooo glad to have a front fender that day, goo all over the bike anyway, but at least my face stayed clean.

If you run a rear rack on your bike, rear fenders can be made from anything, and just attach to the frame and the bottom of the rack. I prefer a strip cut from closed cell foam fatigue mats, mostly since I found those on the roadside too.

dogman, your "road magic" is strong. I like to pick up and keep stuff I find. I have a good pair of pliers, a wrench and a bungee from Road Magic.

JKB

[Kinni420]

road junk can be great. I found a spin doctor bike tool 3456 mm allens, screwdrivers etc all in one.

heres a pic of my PSU completed and several charge and discharge harnesses just waiting for 4mm bullets. Mail is late today and expecting battery charger and the plugs. Guess I should just head out and get a beer and watch some march madness. GO CU!

[Kinni420]

so i get the charger and suddenly the PSU takes a big shit...

resistors get super hot an if i plug in charger everything shuts down

well this was a complete failure

got it to work....carefully watching the heat on the resistors.


seems everything is fine...just forgot to plug in the charger before turning on the PSU

LOL...i got the 4mm bullet connectors but i cant figure out what goes where! since I dont have the batteries yet I dont know which pole goes in which slot so I cant finish my harnesses....little help here?

[dogman]

Sometimes it works, sometimes it don't. Nobody ever overstated the watts their ps really puts out continuously. Now you know why a lot of us like the meanwell ps.

Meanwhile, set the charger to a lower amp setting, and charge slower.

[Kinni420]

I knew you would post while I was preparing this! lol

anyways, ya I understand what ur saying about the PS. regardless. the connectors



Love the little AB Clip EPbuddy sent along with my order. Should do nicely to protect those fragile little JST connectors. Sorry pics so fuzzy notice the soldering iron burn (complete with solder!) in my keyboard

[jkbrigman]

LOL...i got the 4mm bullet connectors but i cant figure out what goes where! since I dont have the batteries yet I dont know which pole goes in which slot so I cant finish my harnesses....little help here?

"Black gets the jack" (socket)
"Red gets the head" (plug)

You can see an example here, on the large piece with the anderson connector on the serial discharge harness.

or the entire thread at:
viewtopic.php?f=14&t=36097&start=45#p540966
This also holds true for your parallel discharge harnesses and your parallel charging harness. When I made mine from white cheap extension cord, I marked the jacks with black heatshrink and the plugs with red.

The two jumpers each have one plug and one socket, so the rule does not apply there, the color of the jumper is irrelevant. All your "jumpers" in the serial harness will have one plug and one jack.

18S_harness.jpg (170.72 KiB) Viewed 450 times

Side note: There are people here who claim you don't need a harness to connect all your batteries in series. That's not true. You CAN connect the plastic battery connectors in series without the "jumpers" I show. But that doesn't get you from 4mm to an Anderson connector and it's a big, bad 3-dimensional mess. Even if you do decide not to make the short jumpers, you still need the piece I show with the Anderson connector.

making a temporary test battery.jpg (134.03 KiB) Viewed 450 times

As you can see in my image where I show the 3 LiPo packs in series, with jumpers, the connections become orderly, easy to manage and flat so they can be folded down against the packs. There's no twist or undue force on the LiPo brick pigtails. I had about 1/4" clearance in the box when I put this pack together and the cables fit beautifully.

JKB

[Kinni420]

completed harnesses

[Kinni420]

heres the bike finalized (minus the batteries )

[jkbrigman]

That frame bag looks great. Harnesses are made. So now you're waiting for LiPo?

I'm jealous. Now I want an upright bike. I need to find myself a good deal on a used mountain bike somewhere....Where's my $150 KLH?

JKB

[Kinni420]

WOOT LIPOS HAVE ARRIVED! charging now!

[Kinni420]

Very first test ride went great!.. did 2.6 miles with very little throttle (breaking in lipos) recharged (3 min each) went out for a slightly harder ride...2.6 miles again but more gas. 2810 is amazing in its torque...almost scared me a couple times lol.

funny thing is my CA registered 7.4 AH used but i never went below 69V....(I is a confuseled collije grad-u-ate)

even the graphs on logview only show me taking 2300 mAh.

now logview is broked.

Ill post pics and video when its light.

getting back to light discharges...cya

[Kinni420]

big ride to and from work.

18s1p, 7.5 miles, minor pedaling here and there, used 2.473 Ah, avg speed of 15, max 25 (haven't really got on it yet), 22.7 Wh/mi, 1.2% uphill slope (+550/-50 elev change)







passed a road biker in full "queer" gear, with a cig in my mouth, going uphill. I havent laughed that hard in years!

P.S. Its not my Rascal!

[Kinni420]

OK full speed test....just had to do this today after the 9th cycle.

http://www.youtube.com/watch?v=XD56SDjr ... e=youtu.be

LOL omg

[dogman]

[jkbrigman]

big ride to and from work.
18s1p, 7.5 miles, minor pedaling here and there, used 2.473 Ah, avg speed of 15, max 25 (haven't really got on it yet), 22.7 Wh/mi, 1.2% uphill slope (+550/-50 elev change)
P.S. Its not my Rascal!

Dude! AWESOME! AWESOME! AWESOME!

Some comments:
1) Wow, your build is "clean" - the bike looks fantastic.
2) I'm impressed with the efficiency - really not that much more power consumption than my recumbent.
3) ROGER WILCO the torque of the 2810. Isn't that one heckuva motor?!?! I love my 2810. It ain't the fastest thing around, but I need a little torque these days.

Questions:
1) Looks like straight-up mountain bike knobbies - what pressure are you running?
2) Can you feel any resistance from the tires as they are, and are you thinking going with something more street later?
3) How's the batteries holding up? Are you able to do your mission with 18s1P?
4) Are you only balance-charging right now?
5) Have you put the bike to "full production" use yet - do you consider yourself done with testing?

Congrats!
JKB