Noobie Smudger's Commencal build.

[smudger1956]

Made a start today...just some minor fettling to get the HS3540 in by way of packing out the disc rotor 1.5mm, the torque arms fell into place, 2 new boots 26x2.2 DMR Moto's.
Have a shed load of Power Poles on their way, and we be collecting 8-5s1p Lipos over the next couple of days, I am privvied to be able to cherry pick from a warehouse full of lipos to ensure no DOA's or low cells..

All the best.
Tony

[Tench]

Hi Tony, its nice to see another uk e-bike builder on the scene. Thats a decent looking frame for the job, the swing arm looks good and strong.
I would be interested to know where you source your lipo, i wasnt aware we had a warehouse full of stock in this country, what make lipo is it?

Cheers Simon.

[smudger1956]

Hi Tony, its nice to see another uk e-bike builder on the scene. Thats a decent looking frame for the job, the swing arm looks good and strong.
I would be interested to know where you source your lipo, i wasnt aware we had a warehouse full of stock in this country, what make lipo is it?

Cheers Simon.

Hi Simon, I get my Lipo's from http://robotbirds.com, the guy who owns it is a mate, the lipo's I will be using are 'PolyPower' (RobotBirds re-badged, same as the ones from H-King....) I will be using the 5s1p 5000mah 20C packs, I have been using the PolyPower 6S1p 5000mah 30C packs in my RC Models, I pull around 35amps 'cruising' and 105amps WOT for extreme aerobatics, can't fault them, they are performing as good as any ThunderPower pack I have owned.

All the best.
Tony

[deecanio]

Hey Tony,
Welcome to the forum, nice to see the uk scene growing more and more
Looking forward to the bike, nice base


D

[smudger1956]

Just a minor update...visit to my Lipo emporium concluded..hand picked packs
Time to get my electrical head on and suss out the install.....

All the best.
Tony.

[M1k3]

Great looking bike and in the uk,have you decided where the batterys will go

[lostrack]

Hi Tony, its nice to see another uk e-bike builder on the scene. Thats a decent looking frame for the job, the swing arm looks good and strong.
I would be interested to know where you source your lipo, i wasnt aware we had a warehouse full of stock in this country, what make lipo is it?

Cheers Simon.

Hi Simon, I get my Lipo's from http://robotbirds.com, the guy who owns it is a mate, the lipo's I will be using are 'PolyPower' (RobotBirds re-badged, same as the ones from H-King....) I will be using the 5s1p 5000mah 20C packs, I have been using the PolyPower 6S1p 5000mah 30C packs in my RC Models, I pull around 35amps 'cruising' and 105amps WOT for extreme aerobatics, can't fault them, they are performing as good as any ThunderPower pack I have owned.

All the best.
Tony

Funny - I bought a load of kit from robot birds, thought they had a showroom/shop and just turned up...it was a warehouse full of cardboard boxes!
Get it finished soon...weathers improving!
I'm NW London - used to live near twickers....

[smudger1956]

Great looking bike and in the uk,have you decided where the batterys will go

Hi M1k3.
I am going to use the same method as Jimbo - viewtopic.php?f=6&t=32754
All a bit tight for space, but I'll sort it.......

All the best.
Tony

[rui_fujino]

great to see UK ebikers! I have still not met one yet tho....:p
By the looks of the price it might be cheaper to get batteries from HK?
what are the charging method ur thinking of?

[smudger1956]

great to see UK ebikers! I have still not met one yet tho....:p
By the looks of the price it might be cheaper to get batteries from HK?
what are the charging method ur thinking of?

Hi rui_fujino

I really CBA to buy from HK, I am privileged where I can go and select my Lipo's, get a substantial discount. I have my goods in hours rather than weeks....If there is a problem..it's sorted in hours..rather than..weeks..
I will be bulk charging.
All the best.
Tony

[smudger1956]

A minor update, been a bit sidetracked with the Easter Holiday....and a Go Pro arriving...
Started to fettle the lipo boxes from ducting, after much faffing about I sussed the Lipo box will have to be 'take off on and onable'..) there is no way I can get the lipo's in with the box in place...
So I fashioned some bracket clamps for the downtube, and a fixing for inside the lipo box. Need to make another 2 brackets to come off the downtube mounts, for the controller to mount in the frame 'triangle'.All looking good....

All the best.
Tony.

[smudger1956]

Err...the Go Pro diversion, lashed it to the 250 watter plodder, and fitted a kiddies seat to take the Grand Daughter for an E-Bike Ride, she loves it, right little speed freak....

ATB
Tony

[Racer_X]

Looking good smudger1956, I have similar photos of my 18mo old daughter, I also believe in the front mounted child seat. My daughter loves it too! She sees me going for my helmet and she start to look for hers.
Quick question how did you manage to cut that flat channel PVC pipe at an angle and get such a clean cut?
I tried cutting some flat channel PVC pipe with a hacksaw and the result was uneven and in some instances it even cracked the PVC.

[smudger1956]

It's getting there..it's getting there...minor update -
All the ornamental iron work finished, just test fitting the controller, lipo box will be mounted to brackets.
More to follow..

[smudger1956]

Looking good smudger1956, I have similar photos of my 18mo old daughter, I also believe in the front mounted child seat. My daughter loves it too! She sees me going for my helmet and she start to look for hers.
Quick question how did you manage to cut that flat channel PVC pipe at an angle and get such a clean cut?
I tried cutting some flat channel PVC pipe with a hacksaw and the result was uneven and in some instances it even cracked the PVC.

Hi Racer-x
Sorry for late reply....I used a Makita chop saw,(at work.. ) does not do the cutting disc any good....failing that I would have used a mitre saw jig.

Smudge..

[Racer_X]

Thanks for the tool tip smudger1956, Looking good. I can not wait to see how you finally mount those PVC pipes in place.
One thing I would recommend is that you place the controller with the wires exiting towards the bottom so that if you get caught in a down pour the water does not leak into your controller.

[smudger1956]

At bloody last……………….finished……………….
Managed a test ride last night at 8.30pm..when it finally stopped raining……set the X-Lyte CA to 25amps while I am ‘commissioning’ the LiPo’s, major grin factor or what….the Commencal handled real well, I am so pleased, and I cannot stop grinning……………
A few minor cosmetic embellishments to carry out, need a play with the Trip/Speedo, it’s a bit out I think due to the 2.2 tyres.
Unfortunately will not be able to ride a lot, another minor workathon for the next 4 days, but I am going to enjoy my ride to work…..
A thanks to all for the input.
All the best
Tony

[rui_fujino]

great build but looks like your front suspension and your battery case might be little too close?
I think If you jump off somewhere high your tire might touch the battery case...

[smudger1956]

great build but looks like your front suspension and your battery case might be little too close?
I think If you jump off somewhere high your tire might touch the battery case...

Hi rui_fujino
Yes it is close, but that is as far 'back' I can mount the lipo case without hitting the chain ring, I cannot lock the suss, but trying out various air pressures in the forks, I got it to a point where it will not hit the case under 'normal-ish' conditions ( coming off a kerb ) for example.

[Racer_X]

At bloody last……………….finished……………….

Turned out great, I guess as Rui has pointed out you have some adjustments to make. Otherwise a great build, I bet it handles awesome.

[kudos]

Smudger,

What mount method are you using to mount the APM centrally on your bars, I can't quite see from the pictures...?

Cheers,
Kudos

[smudger1956]

Smudger,

What mount method are you using to mount the APM centrally on your bars, I can't quite see from the pictures...?

Cheers,
Kudos

I made a bracket from 1.5mm Ali sheet, and clamped it in the stem, I'll take some close up pics and post later.

Cheers.

[smudger1956]

APM-Mount.jpg

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APM-Mount2.jpg

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There you go, I used a rubber strip to take up the gap in the handlebar mount clamp, had to bend it a bit more which cracked the paint...........
And mounted a 'Type approved' reflector, which just has a cable tie going through it and around the bar mounts of the APM ( Just done this to make it UK legal..tic..)