First Time Rear Hub 48v Build

quickshot23 · Mar 17, 2014

Hey guys,

This is the start of my build thread:

About Me:

28 Year old Father/Husband
In school for Network Administration
Love anything and everything electronics and speed related

I come from a RC background where I build pretty fast RC cars and loved it alot

See some of my Random RC videos here (electronics/speed addiction):
https://www.youtube.com/watch?v=JYqoKU2DXvg
https://www.youtube.com/watch?v=-1SImpPhHyY
https://www.youtube.com/watch?v=WHi_ou0oHrg
https://www.youtube.com/watch?v=3dy_6QFZ1vI

And one of me selling my beloved cbr 600 : ( (speed addiction)
https://www.youtube.com/watch?v=tkjI4tr0D4U

Anyways onto the Build : )

I bought a used bike to begin the build because my junk walmart bike wouldnt cut it : )

Build List:

2009 Giant Boulder SE in great condition
A Crystalyte 406/4011 Dual Speed Hub Motor - Thanks DAND214 for the great deal : )
BMS 12 FET Controller - Thanks DAND214 for the great deal : )
4x Turnigy 6s 5000mAh 20c/30c Lipos run as 44.4v 10Ah
Custom Fiberglass enclosure for the batteries and controller (I will take pics as I build) - First time working with fiberglass

I will post pictures of the Bike and as I work with the fiberglass.

I will update this thread as I build the bike with pics/videos

Thanks for reading

God Bless

quickshot23 · Mar 19, 2014

I am getting ready to order the spokes for the wheel - A bit nervous about this ERD stuff as I have never done it

Hopefully my calculations are correct : )

friendly1uk · Mar 19, 2014

Measure the erd yourself. Then take away the hub diameter (measured at the spoke hole centers) and divide the answer by two.

quickshot23 · Mar 19, 2014

Here is what I came up with

Does this look right?

Your advice is greatly appreciated : )

friendly1uk · Mar 20, 2014

Looks good to me

I actually have 38 spokes at 186mm each, doing nothing. I can't imagine postage being kind, but if your getting terrible price quotes then It might be worthwhile. 285g +p&p So 5 days looks like $11 if they don't start demanding I buy some daft international label pack

quickshot23 · Mar 20, 2014

I should be good on ordering the spokes

decent priced local shop

im just nervous about ordering the wrong size

quickshot23 · Mar 20, 2014

Spokes ordered (fingers crossed)

I ordered:

40x http://www.danscomp.com/products/435905/Sapim_Stainless_14G_Spoke.html at 186mm

1x http://www.danscomp.com/products/811241/Finishline_Teflon_Lube.html

1x http://www.danscomp.com/products/449026/Velox_Cloth_Rim_Tape.html

cal3thousand · Mar 20, 2014

186mm seems to make sense only if you are running a radial lace pattern. And on a hub motor, I would run a 1X lacing pattern. Which puts your spokes at ~191mm depending on the distance between the flanges.

EDIT: Use this site for calculating spoke lengths

BTW, I've never heard of the (ERD - HUB diameter) / 2 formula ever before.

quickshot23 · Mar 20, 2014

Here is the spoke calc - I really hope my calculations are correct - I did it the way suggested (divided by 2) and also using this calculator and it came out the same

Check out the picture and let me know what you think

cal3thousand · Mar 20, 2014

You have 172mm in the image as your flange diameter and in the calc you have it as 188mm

Which one is correct? I used 172mm to get to ~191mm on the spoke length

quickshot23 · Mar 20, 2014

I looked it up 2 ways - I found a random PDF from Crystalyte: http://www.crystalyte.com/Dimensions_SAW_rear_motor.pdf - I am not sure if this is the same Hub motor....

The number I used when determining the size to order was the stored one within the calculator: http://www.ebikes.ca/tools/spoke-calc.html Clyte 400-Offset

This stored all the values for the hub motor

To determine the ERD I followed this youtube video and measured the rim and added 2mm to each side for rim wall thickness: https://www.youtube.com/watch?v=EoJJI7FRZLk

With that calculator it gave me the 186.1mm

Do you see any flaws in my numbers : / ?

quickshot23 · Mar 20, 2014

The make-it-or-break-it questions is: Is the "Clyte400 Offset" the same as the Crystalyte 406/4011 motor I am using?

quickshot23 · Mar 20, 2014

Will have Bike pics and motor pics - Also, any new items that arrive tomorrow : )

Stay tuned...

quickshot23 · Mar 23, 2014

Initial parts/Bike/and other misc. build pictures coming tonight : )

quickshot23 · Mar 24, 2014

Allright - First Build Pics

Here is the Hub Motor I am installing:
url=http://s241.photobucket.com/user/samari23/media/IMG_20140324_183727.jpg.html]

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Here is my Rim before I attempt my first hub motor and first re-lacing : )

After Spokes are removed:

New Sapim Spokes and Nipples:

Everything installed and waiting to be trued:

Successful day : )

Tommorrow I am Truing (sp?) and then hopefully adding Deans Ultra to my 6s Lipos

Thanks for tagging along : )

God Bless

quickshot23 · Mar 25, 2014

Here is my box from Hobbyking - 4x 6s 5000mAh Lipo's:

quickshot23 · Mar 25, 2014

Finished truing my wheel

So glad I did it myself...was pretty easy

Tomorrow my deans ultra come and I will also begin my fiberglass battery box.

I will document the build.

Any advice on a frame support that I can build myself?

quickshot23 · Mar 26, 2014

Cell voltages excellent:

Lipo # 1 Total Voltage: 23.00v
Cell 1: 3.83v
Cell 2: 3.83v
Cell 3: 3.82v
Cell 4: 3.83v
Cell 5: 3.83v
Cell 6: 3.83v

Lipo # 2 Total Voltage: 23.00v
Cell 1: 3.83v
Cell 2: 3.83v
Cell 3: 3.83v
Cell 4: 3.83v
Cell 5: 3.83v
Cell 6: 3.83v

Lipo # 3 Total Voltage: 23.00v
Cell 1: 3.83v
Cell 2: 3.83v
Cell 3: 3.83v
Cell 4: 3.83v
Cell 5: 3.83v
Cell 6: 3.83v

Lipo # 4 Total Voltage: 23.00v
Cell 1: 3.83v
Cell 2: 3.82v
Cell 3: 3.83v
Cell 4: 3.83v
Cell 5: 3.83v
Cell 6: 3.83v

Began soldering the deans ultra on - hopefully will have them on tomorrow with all harnesses (series and parallel) put together so I can get a first power up test (I will take a video and post it here)

tomtom123 · Mar 28, 2014

very nice, i look forward to the updates and how you will make the fiberglass case, i could use some ideas

quickshot23 · Mar 29, 2014

You know, I was thinking about the fiberglass case and I did some searching and ebay has some cloth cases/bags that would fit in my frame "triangle" perfectly.

Now, I am not one to quit on an idea but, removing the fiberglass every day to charge or having to open it and remove the batteries daily seems like a pain when I can just pull the velcro off the bag.

I am still considering which way to go but im leaning towards the bags.

Any advice is appreciated

Also, I have to solder up 2 parallel harnesses and fix some vertical wobble in the wheel and it is ready for a test ride

Thanks for following along

God Bless

quickshot23 · Mar 30, 2014

All harnesses made (1x Series, 2x Parallel)

All connectors soldered and heatshrinked onto batteries, controller, and charger

All Batteries Charged

I need to do a final balancing of the wheel, adjust the rear derailleur, and the front derailleur.

I need to mount everything on the bike, (Purchased the bag to mount but will do a test video for you guys with a mock up bag this week)

I will take pics of the motor on the bike soon

Thanks for tagging along with me on my first build

God Bless

quickshot23 · Mar 31, 2014

Frustrated with adjusting the derailleurs

Doesnt seem to be working as it should...

I will work through it and then post a running video when I get it set

Stay tuned...

CroArcher · Mar 31, 2014

If you are using more than one gear on ebike,you are not using it properly

quickshot23 · Mar 31, 2014

I hear you but I like peddling as well - and also, I do want the bike to operate properly if I were to need to use it as a regular bike

In other words, I want the bike to be 100% operational before I go riding it as an ebike

: )

I will get it set up, it is just a hassle (especially when the batteries are charged and the bike waiting to be rode : (

Thanks for following along

God Bless

quickshot23 · Apr 3, 2014

Ahhhh finally....

Front and rear derailleurs setup perfectly...

Now I must correct the wheel-wobble (made up terms : )

Once this is done...im mounting the electronics and making some videos

I promise I will take pictures of the bike soon

First Time Rear Hub 48v Build

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