GT i-drive 2.0 Build

[Hyena]

might get around to playing with the hs3540 this weekend

You won't want to go back to the 9C once you do. Don't go trying to jump it though, I reckon the extra weight will finish off whatever is miraculously holding your bike together

Oh, and you'll need that extra voltage in your pack, they're thirsty buggers when you nail it.
I take it you pulled the lid off your charger and turned it back down a little after it slightly overcharged your pack last time?

[GCinDC]

man it's good to have you back, hyena! there were a couple dark weeks there...

yes, i dialed down the voltage on the charger to 83.4V and all the cells are reasonably well balanced.

good to know that the hs3540 will be thirsty. i'm not sure if it's the cold now or the fact that my pack is > 500 cycles, but there's quite a bit of sag under load. maybe 6V or so?

i had to grind the 9C axle a bit (to round the top) to fit it in the dropout, and i've not wanted to do that unecessarily w/ the hs3540, if a new bike's dropout won't need it... so that will be something to look at.

also, since the wires are short, i'm trying to decide how to create the extension - i've had my problems w/ andersons you know, so i'm inclined to cut them and solder a waterproof extension that will go up the controller, rather than add new connectors down there (in the way of the bike trailer hitch....)

i sent jason my highlights and he posted it on fb: http://www.facebook.com/pages/The-E-Bik ... 4480066788

[GCinDC]

updates
- too dark to record am commute, little new on return commute.. no jumps so generally depressed..
- rear tire wobbling a lot, ometimes rubbing frame, keep forgetting to order replacement spoke!
- rear tire rather bald
- hi power permanent mount flashlight switch button doesn't work, so no light, now when i most need it...
- nice crust of salt (from marine corps marathon, wtf?) is all over rear/underside of bike
- some ahole keeps unplugging my charger in the parking garage, sometimes right after i park, pissing me off extremely
- no time to play w/ hs3540, and need commuter so can't afford to leave job halfway
- been picking up 6yo at school w/o trailer - he climbs on in front of me, puts his feet on my feet, sits on toptube, holds handlbars, no helmet, but it's only .75 mile to home

now, dbaker, since you've got 50 ebikes and not one build thread (and only signed up ES to PM me to buy the GM motor 2 years ago), i've got to ask you in my thread: WHAT HAPPENED WHEN YOU GOT HIT BY THE CAR?? REAR ENDED ON A NON-ELECTRIC RECUMBENT BY AN SUV?? tell us the (cautionary) tale, how the healing is going, how the insurance is going, and how commuting on the electric 'snow bike' is going - still got lawyers yelling at you on the trail??

[knoxie]

updates
- too dark to record am commute, little new on return commute.. no jumps so generally depressed..
- rear tire wobbling a lot, ometimes rubbing frame, keep forgetting to order replacement spoke!
- rear tire rather bald
- hi power permanent mount flashlight switch button doesn't work, so no light, now when i most need it...
- nice crust of salt (from marine corps marathon, wtf?) is all over rear/underside of bike
- some ahole keeps unplugging my charger in the parking garage, sometimes right after i park, pissing me off extremely
- no time to play w/ hs3540, and need commuter so can't afford to leave job halfway
- been picking up 6yo at school w/o trailer - he climbs on in front of me, puts his feet on my feet, sits on toptube, holds handlbars, no helmet, but it's only .75 mile to home

now, dbaker, since you've got 50 ebikes and not one build thread (and only signed up ES to PM me to buy the GM motor 2 years ago), i've got to ask you in my thread: WHAT HAPPENED WHEN YOU GOT HIT BY THE CAR?? REAR ENDED ON A NON-ELECTRIC RECUMBENT BY AN SUV?? tell us the (cautionary) tale, how the healing is going, how the insurance is going, and how commuting on the electric 'snow bike' is going - still got lawyers yelling at you on the trail??

Get one of those little spy cams greg and film the pesky charger unplugger, I suggest you dont leave your gopro there though just check ebay for them, I got one from HK its fine for strapping to the radio controlled car, or for catching pesky folks in parking lots and was so cheap it didnt matter

[dbaker]

Good idea with the spycam!

Healing slow. Big patch of road rash above my hip. I need to wear a diaper

Haven't worked the police report / insurance. Too busy with work and Sam. Tomorrow

Trail has been OK. I go slow and try to stay 20mph around other bikers. You should come over this weekend and get a spoke. I can't believe you don't have some you can take from some of your trashed motors Was this a special build or the standard 9C from ebikekit?

My 9C in a 24 inch rim (Hookworm) and 18 fet on 24s2p lipo will probably do 50mph. I get 45mph on the dip under 23rd street.

[GCinDC]

time to dig out the spycam. in the meantime, i confronted the hvac guys who smoke near the bike rack and they said they didn't do it but maybe the sup did. he parks right next to the outlet. i did leave my card w/ a note at the outlet tho...

I can't believe you don't have some you can take from some of your trashed motors Was this a special build or the standard 9C from ebikekit?

tried that. other 9C spokes don't fit. spokes were JRH custom.

i need to get a pic of that intense. it's a sweet bike.

so did you not have a blinkie on the back? this is a recumbent's nightmare, right? would it have been worse on the regular bike?

[dbaker]

Probably worse on a regular bike. When the bike got hit I stayed on the bike but the rear wheel was destroyed and could not turn. The recumbent seat was able to launch me; a regular bike would have been launched and I would have been on the windshield.

[GCinDC]

another way to fix a broken spoke...

IMG_20111113_104343.jpg (146.82 KiB) Viewed 544 times

[dbaker]

How is caliper clearance to the hub?

[ambroseliao]

another way to fix a broken spoke...

How does it perform?

[GCinDC]

How is caliper clearance to the hub?

~1mm now, after grinding about that much off the tops of some bolts (bike's original calipers)

HS3540 Install notes:
+ wires coming out axle side meant no more threading wires thru bolts & washers.
- short motor wires meant connections on the chainstay which can get hit by pedal and will need special waterproofing treatment.
+ phase wires are like double the size of the 9C!
- motor/wheel only came w/ 2 washers & nuts... i've always had washers on the inside as well as outside, to prevent the dropout from splitting when the axle nut is tightened
- the plastic bit on the wire side? too lazy to go back and read 1000 pages on it, but didn't like how it was looking when i attached w/o inner washer there.. started to compress like washer... any suggestions/warnings about how to care for those plastic bits?
- thank god i had extra freewheel spacers... without one, the (7sp 11T) freewheel jammed against the motor! i woulda been pissed about that. note to methy to ship them and washers.
+ disc rotor install was fine, despite terror of stripping the holes. used small torx wrench and tightened just about as far as i could.
+ calipers have a bit more clearance than 9C, perhaps 1.5mm, which was enough for me to work with...
- wheel was fairly true, but the spokes were rather loose. i rode it around a couple miles and then tightened them up very firm.
- the spokes/spoke holes won't have a chance against the winter salt. i'm thinking the anti-corrosion spray and maybe even caulk, once the wheel settles some more..
- got hall/phase wiring combo on second try when on bench, but once installed, the motor went backwards! after a couple more attempts, i googled and found the right combo.

How does it perform?

Mixed emotions so far. Performance notes:
- didn't notice a big difference right away, perhaps just diff between v-6 and v-8..
- different sounds to get used to, hard to explain.
- seems not as fine control at low speed. slight lag at WOT?
- a bit more torque there, but no wheelie machine!
- feels heavier for sure.

- above 15 mph when i let off accelerator, regen engages like normal, but when i hit the brake as well, it sounds like there's an extra surge of regen that i never had before. i don't mind it, but i keep thinking the axle is shifting in the dropout! but perhaps it's just more regen current, care of the bigger phase wires?

anyway, dbaker was curious about the hs3540 and wanted to compare w/ his (6x10?)9c on a 24" wheel w/ 24s lipos and a 100V/100A 18fet to compare, and i said it sounds like you want to RACE!

and i whupped him! but ONLY because we SWAPPED bikes!!! his bike would have killed mine w/ an 18" wheel! it was getting dark and there wasn't anywhere nearby to really get up to speed, so we just did a couple quick countdown starts.. but there was no comparison:

correct me if i'm wrong on your specs, dave... what was your max amps? mine was around 60A @ 77V, so 4.6kw vs your, what 7kw? it would be interesting to see how they'd compare w/ same batts/controller.

... so i cried myself to sleep last night. wept like a baby. if only i coulda drawn more power on his and burnt his 9C.... lol.

this morning was the real test though: the commute!
+ i did notice more speed, particularly midrange, though there's not a ton more torque. turning the throttle doesn't help much beyond a certain point, just seems to saturate the motor.
+ and down the hill under dupont, got easily up to 48mph.
+ upon dismount, i was like what's that smell? peeiou - oh yeah, new motor. i could stand touching it for about a second.
+ CA readings:
MaxS = 48.6mph
Amax = 79
Amin = -12.4

[deecanio]

Greg,

hopefully you did the mod on the plastic bits? you dont want to be replacing the motor wires for a ten minute fix!!
Essentially you need to remove the inner seal and reverse the plastic bit to keep the cables from rubbing.

D

[GCinDC]

hopefully you did the mod on the plastic bits?

cringes... hmm... i'd assumed methods did that prior to sale... i didn't ask him specifically, but he says this on his sale thread:

...Warranty...So we are clear - the purpose of this warranty is to alleviate concerns about recent quality control issues that Crystalyte has had regarding "cut wire" issues with their motors. This is not a guarantee that you wont smoke your motor, that your spokes wont get loose from over-powering, or that your controller wont pop if you push it too hard.....

and nicobie's followup:

...It's a shame that so many people had trouble with the first few batches. The wire cutting problem was an easy fix, but if the customer didn't know about it, he couldn't fix it...

EDIT: just emailed methods. confirmed: he did 'cut wire mod' before shipping.. <phew>

[chroot]

I watched the youtube vids - Greg - you wore the yellow jacket? Cuz hard to see the youtube video. If your friend used the 100v and 100A will beat you no matter what your HS35 had set up from your old 9C 45A. You will lose to the 100v 100A ebike.

Correct me if I am wrong.

[GCinDC]

...You will lose to the 100v 100A ebike...Correct me if I am wrong.

what about rider skill??

just kidding. of course i lose! haha. by how much was the question... i was riding dbaker's bike, dbaker (with yellow) on my bike..

results may be in doubt tho... this morning when i took off, i noticed the speed switch was set to 1!

we might need to have rematch...

but i rode his bike. i felt it. i know i will have no chance on mine...

[dbaker]

Need to try smaller diameter wheel; 24" or 20".

[deecanio]

all good then mate, just wanted to be sure to save you the pain
rock on - btw Greg, your running that with a 12 fet lyen yes? need to copy the wiring colours.

D

[GCinDC]

perhaps v8's don't like city driving as much as the open road...

my early comments on this motor were made prematurely... it hauls ass! might take a minute. but she's got more 'bottom', no doubt. particularly above 20mph..

fiftypointthree.jpg (79.86 KiB) Viewed 384 times

and i'm pretty sure that's not top speed... it was downhill, yes, but in traffic so i was surprised it got up that high. i had my phone My Tracks program running but it failed to record the speed. there will be other opportunities however.

please remember that my old 9c had stock TINY phase wires, probably why i never fried it, and that my controller is limited to max 45A, so these are new levels for me!

IMG_20111115_073420 (1).jpg (66.44 KiB) Viewed 384 times

good thing my commute is only 15 minutes (and shrinking). and it's wintertime.. cooling will be an issue in the summer and on longer rides, esp if i don't manage the throttle...

Need to try smaller diameter wheel; 24" or 20".

ohhhh, i didn't get you at first... but you mean I should try smaller wheel so i can get more torque off the line, right? and then we can race! i'd thought you meant you should go down to 20 so i'd have a chance... i'd love smaller rims, particularly if i could have bigger tires and less air pressure... i love watching those trials bikes with like 5 psi!?

btw Greg, your running that with a 12 fet lyen yes?

thanks for heads up, D. caused a mild panic, but now i'm sure. <phew> and yeah, i might as well reprint these for (my own) future use!

HALLS
Y >Y
G>B
B>G

PHASE
Y>B
G>G
B>Y

[dbaker]

So you could trade some of that top end for more torque off the line by going to a smaller diameter wheel. What does Justin's program show when you compare them?

[GCinDC]

So you could trade some of that top end for more torque off the line by going to a smaller diameter wheel. What does Justin's program show when you compare them?

when i compare what? wheel sizes?

ps. your 9c is 9x7 or 6x10?

[GCinDC]

[deecanio]

dammit can't se the vid at work
Sorry for causing the panic but i didn't want you having the aggro, and being as i done it myself i knew it was easy as to fix.
Thanks for posting the colours, saves me searching!! looking forward to seeing this vid, i take it your pleased with the 3540? - my plan is to buy a second controller from lyen and have that one beefed up to the max, i'll be keeping one standard as a spare

D

[GCinDC]

working till midnight D? dang. just vid of me, model ebiker. almost smashing car in front. meant to call it 'nice brakes' - cause im very happy about the rear disc! i totally need them now too. i went about 3 wks without rear brakes so am happy!

[chroot]

so did you finally beat dbaker when you forgot set mode 1 switch? Nice close call hit the vehicle when you went hard braking.

[dbaker]

9x7 Did you see that zombiess hit over 50mph on his 9C 20" wheel with 30s