some update on this project...
I have updated the page 1 with all the data I collected so far as well as all the meaningful pictures.
After 1000km done on the bike, I changed the tire and took a few shot at the dropout to make sure it was not cracked or geting damaged:
So far so good, no sign of fatigue.https://dl.dropbox.com/u/78649823/E-bike/Aline/dropout%20after%201000km.JPG
I also changed my led lamp holder for a taller version. This way, they now clear the box. Those magic-shine leds are very bright on the max intensity setting.https://dl.dropbox.com/u/78649823/E-bike/Aline/new%20led%20holder%201.JPG
The mud is an issue on a DH bike, mainly if you want to reach your workplace and stay clean.
I made an adapter in delrin that fit the pocket in the rear frame and added a fender that help at least to keep the rear chuck and my pants clean:https://dl.dropbox.com/u/78649823/E-bike/Aline/rear%20mudguard%201.JPGhttps://dl.dropbox.com/u/78649823/E-bike/Aline/rear%20mudguard%202.JPG
Since the Seahorse box is waterproof and there is limited air flow inside, I was worried about the battery temperature inside the box.
I designed and added a holder + temperature sensor to monitor it while running. ( temperature sensor is inside, near the top of the box )
After several rides under hot and sunny days, the internal temperature never reached 40 deg C.https://dl.dropbox.com/u/78649823/E-bike/Aline/tmp%20holder%201.JPGhttps://dl.dropbox.com/u/78649823/E-bike/Aline/tmp%20holder%202.JPG
I also adapted the GPS holder on top of the box:
Bolted from inside the box, (sorry about the muddy picture )https://dl.dropbox.com/u/78649823/E-bike/Aline/GPS%20holder.JPG
Temp sensor + GPS in place:https://dl.dropbox.com/u/78649823/E-bike/Aline/tmp%20holder%20with%20gps.JPG
I bought a 5 led rear reflector that have a vibration sensor + a light sensor.
This one will activate by himself when its dark outside and stop after 4 min of "no vibration" activity.
Since no useful bracket came with it, I decided to make a decent one custom fit to my rear fender:https://dl.dropbox.com/u/78649823/E-bike/Aline/rear%20lamp%201.JPGhttps://dl.dropbox.com/u/78649823/E-bike/Aline/rear%20lamp%202.JPGhttps://dl.dropbox.com/u/78649823/E-bike/Aline/rear%20lamp%204.JPG
Here is the current look after those modifications:
So far, I did 1800 km ( 1125 miles ) on this build, and the average charging cost is 0.20$ / 100km ( 60 miles )
I really enjoy this bike.https://dl.dropbox.com/u/78649823/E-bike/Aline/full%20aline%20bike%201.JPG