Hyena's e-bike builds (now with HD video)

[Hyena]

Here's a quick video I shot yesterday in the national park near my house.
It's a bit shakey because I accidently left the camera zoomed in a little and its duct taped directly to my handle bars. At 2 mins I was throwing the bike around alot and going fairly quick on that concrete path.

[Hyena]

2 pics from today. Behold the glory of lipo
This is the final configuration for this bike.
I have 60v10ah of new lipos that I was going to use for this bike but I might leave it complete as is and start on a new project
It'll be a RWD this time so I can use some better forks and brakes up front. It'll also facilitate better wheelies


http://img269.imageshack.us/img269/1152/hyebike1.jpg


http://img56.imageshack.us/img56/7503/hyebike2.jpg

[icecube57]

Time for you to join me in the 40mph club only 25 more volts.

[Hyena]

It's tempting, but I reckon 60v will do me for now. For my new bike I'm configuring my cells so they can either be run as a 60v10ah speed pack or a 42v15ah range pack. I could always add the 120v 5ah option for short range insanity, but I'm sure that'd end in any combination of smoke, tears and broken bones

Next time I have cause to take the wheel off I'm very tempted to give star-delta wiring a go.

[mwkeefer]

Hyena,

Nice video... good too see someone else moving their camera around and even leaving it lay out so you can shoot oncoming and leaving shots = )_

Ive gone over the thread and ... for the life of me I cant see how that pack under your seat is 15S2P... it's too small.

Also where is your controller mounted?

The build is clean, I really love the last 2 pics... still wondering about that seat battery = )

-Mike

[Hyena]

Hi Mike,
Thanks, more and better videos are to follow shortly.

You are correct, that pack is NOT the 15S2P!
That's my old 12S2P 8ah. It was very small, I fit fitted 6S2P in 2 zippy boxes and then duct taped them together. They delivered their quoted capacity but sagged like a fat lady.

This is the current incarnation of the bike running 15S2P turnigys in a stainless steel box I made up. I've also added BMX style handlebars for more comfortable riding. The controller is on the handlebars, which makes the wiring for the front hub and wattsup meter easy.

ghettobatt.jpg (70 KiB) Viewed 1404 times

I haven't gotten around to making up mounts for it, largely because it'll go on another bike soon so it's currently ghetto tied onto this bike with an inner tube. It holds it firm though, even when taking a beating over rough stuff like this

bushbash.jpg (187.25 KiB) Viewed 1396 times

While I'm posting pictures

This is my new bike I'll use on a daily basis for riding to work.



I'll be running a magic pie high speed motor and probably a 12S2P turnigy pack.
I was going to use my current 15S2P but I'm not sure if I can fit it there and clear the front deraileur.
The packs just fit themselves but by the time I put them in a box they are a tad too big. I might be able to rework the box and have the wiring leaving the top of the box instead of the end thus recouping an inch which might just make it fit.

battery-newbike.jpg (157.58 KiB) Viewed 1395 times

Other works in progress (hopefully over the xmas holidays) are a custom cruiser (frame build by aussie jester)
This is a photoshop of how I'm planning it to turn out




Not sure what motor I'll use yet, I was thinking magic pie too but I might go with something beefier that I can up the current on.
I'd like it to be able to get up to around 60-70km/hr so I'm thinking maybe 18S2P lipo with a controller around 50a.
Batteries will go in the tank section with room for the controller and more batteries if needs be behind the seat post.
I think you said you were getting those sort of speeds from your 9C and modded infineon controller on 15S so with the extra few volts on board I should be able to do it.

[Grinhill]

I see you have a Cell bike, Hyena.

I love my bike, it's rock solid and hasn't missed a beat. Great spec for the $$$.

[Hyena]

Yeah and with a name like Cell they're just begging to be electric powered For the money they're hard to beat - Al frame, deore gears and a decent front fork for a bit over $400. The only thing it doesnt have is disc brakes, but for a bit over $100 I can throw some juicy 5 hydro discs up front.

[dequinox]

This is my first post on these forums, and I really like the setup! Nice job!

PS where did you get the power analyzer? Was it relatively cheap?

[docnjoj]

Man, AJ still does great work! Nice lowrider!
otherDoc

[Hyena]

Dequinox, it's a wattsup meter. They're available from hobbycity.com, ebay and a few other places.

Man, AJ still does great work! Nice lowrider!
otherDoc

It's not built yet Doc, that's just a photoshop of the design I've come up with. It should be pretty sweet once the master starts doin his thing

[Hyena]

Well, my red bike is no more.

I was on my way to work last week as usual, belting along and came up behind a guy in lycra. He was holding me up a bit but I sat behind him for a while then decided to go around - gave it full throttle went past then jumped over a large speed bump. As I landed I went to pedal and the chain locked then BOOM, my back tyre locks up and I'm fish tailing down the street at 50-60km/hr taking up most of the road. The guy went racing past a few seconds later and I must have looked like an epic douche like I did it on purpose. I'd welded up the handlebars, fork and a rack on the back but not the frame. Geez I dunno, when I buy a bike from kmart for $150 I expect it to last more than a year of jumping off gutters at 50km/hr and high speed offroad bashing

So anyway thats the end of that bike. I was going weld it up and reinforce where it broke but I'm going to start over with a sturdier frame

[Hyena]

I thought I'd ressurect this thread with some updates.
I axed the magic pie from my bike pictured a few posts up and decided to stick with their better performing old motors.
This is my commuter bike so I wanted to keep it as minimal and neat as possible.
It's running my old 15S2P lipo pack I've used on previous bikes with a modified bmsbattery controller for around 2500w peak. 8" avid hydros up front and regen + vbrakes on the back. I've got got the matching 7" rear hydro disks to fit too but haven't gotten around to it yet and I don't know if I'll actually bother - the front does most of the braking and a few times I've had the back tyre start lock and skid because I'm braking so hard with the front it's lifting the weight off the back. The GM hub has been relaced into a wider X5 rim, I may redo it later into a black one so it matches the front. I'm quite pleased with my first attempt at lacing a wheel. It's slightly out of true but still usable with V brakes so not too shabby.

I've neatened the stainless steel battery box I made a while back, it's no longer held on by inner tubes which is a huge leap forward although I have at this stage I've only replaced it with blue duct tape. Yes Aussie Jester, a travesty I know It's pretty neat but I'll probably replace it with stainless straps when I get around to it. I still have 2 wrists in casts so I can't do too much for the next month.



I've got a new MAC motor here I want to try too and that may end up finding its way onto this bike. I've gotta either drill the spoke holes on the hub or get some new spokes though, the 12ga ones I ordered don't quite fit. You can jam them through if you're dead square on but there's no room to get them in at any sort of angle, which I need to do for many of them.

I've got a keen apprentice to help me out though

[drewdiller]

Ok, I'm convinced. My next build will have to use lipo batteries, those things are tiny!

[Hyena]

Yeah lipo is awesome. The size, weight, stupidly high C ratings - I wouldn't use anything else now.
That 15S pack gives me up around 60v for half the discharge too so it performs quite well.

In related news I laced the MAC tonight.
I only had to drill every flange hole for the outbound spokes. I wasn't expecting the alloy case to be so rediculously soft - it literally took 1 second with the battery drill to go right through. I also had to drill the DM24 rim for the 12ga nipples to fit though. Of course I noticed this after I'd laced half the spokes and went to tighten them up a little more. DOH!
I might paint the side covers black and leave the rest silver - largely out of boredom.

[AussieJester]

I might paint the side covers black and leave the rest silver - largely out of boredom.

Have you ever seen hammertone paint finish? ...I would suggest going for this finish but without using the paint Hyena, just using a ball peen hammer and alot of force you should be able to get a nice 'hammertone' finish

KiM

p.s you put the my little pony stickers on right after you took the pic didn't you mate? didn't you? you did dindn't you? YOU DID ?! admit it!! ADMiiiiiiT!!!11

[Hyena]

Have you ever seen hammertone paint finish? ...I would suggest going for this finish

Great minds think alike, that's exactly what I put on it this morning.

but without using the paint Hyena, just using a ball peen hammer and alot of force you should be able to get a nice 'hammertone' finish

Oh, disregard the above

No my little pony stickers, I don't have the patience that you do to sit down and cut them out

[Hyena]

So my little camera I previously used to make my videos died for no particular reason, it just doesn't seem to record any more. After having issues mounting the camera so it recorded exactly where I wanted I found the perfect solution, some spy camera sunglasses

Very cool in theory, unfortunately they're crap... They need resetting with a pin every few times you use them and you only get a decent picture 1 in 5 times you record. It'll either not record at all, record sound but a blank picture or record all in one colour (eg all blue or purple). Pity, I'd happily pay double the price if they worked properly.

I dont know if they're all like that, they worked fine for the first few uses then stopped working properly.
Here's a quick demo incase anyone after a small cheap recording solution wants to have a $20 lucky dip and hope for a good pair.

[OneWayTraffic]

Hey you should put the LiPo in one of these. I've just ordered one from England for the kit you're sending me. If it will fit LiFePO4 then it will fit LiPo for sure.

http://www.carradice.co.uk/index.php?pa ... duct_id=31

That's a big ass seatpack. It was actually cheaper than anything I could find for battery mounting in NZ, even after I paid for postage. Total cost $50NZD and should be a nice clean removable install.

[thewmatusmoloki]

I was actually just about to buy a pair of those video sunnies, thanks for the timely warning.

Iv'e already got the mp3 sunnies ($25) off ebay, they've got 2 gigs of memory for mp3's work 95% of the time ok and the're loud. Which is acceptable to me for the el-cheapo price. They are my ebike stereo (used with caution and never in heavy traffic area's).

Matt.

[Hyena]

Yeah Stuart that's a good solution, and indeed a big ass bag! I could squeeze 18S5P of lipo into that!!

Matt if you're not terribly fashion concious it's almost worth the $20 gamble to use them as a normal pair of sunnies!

[TPA]

I found the perfect solution, some spy camera sunglasses.

Pity, I'd happily pay double the price if they worked properly.

Sounds like your plans for a trip to the beach were ruined

[thewmatusmoloki]

^ =

[thewmatusmoloki]

But if I had bought a pair of those, it would only be for videography of the ebike ......... honest.

[Hyena]

As I mentioned in another thread somewhere, the footage while riding would look something like

*footage of riding along*
*camera pans to the bum of a hot girl on the footpath*
*rapid motion blur*
*flashes of road, sky, road, sky, road, sky*
*camera comes to rest showing a side angle view of the road*