Evolution of Skill....

[Arlo1]

You should get someone to mesure the 5303 for inductance my 5304 is 255uH so I would guess yours is ~ 143uH which should not eat controllers. But what controller was it you just popped? I use settings a little under that on my 12 fet with 4110 fets. and as a rule 2.5x ratio from battery to phase amps.
This is again an example of a china controller with not enough proper hardware to keep it self alive. All it would probably need is a fast phase current sensor and it would most likely be ok.
Another rule I use with china controllers is I never run more phase amps then 40% of the max HOT (100degC) rating of the fets.

Arlo, thanks for the input - the controller is a LYEN 18X4115. I would imagine someone here has measured the inductance on a 5303 due to their in-famous history of eating controllers....

I pm'd bunch of folks and they are all providing similar input - either get an 18X4110 and be careful with the settings, or get a 24 fet and be done with it....

Len

Yup 4115 mosfets are very weak. 4110 are a lot better. Lower RDSON meens less heat.

[Lenk42602]

Bike is back up again. 18X4110 controller V2. Waiting on the new jumper cable that is need with the new version boards in these controllers. Will be holding my breath until I get some miles underneath her.....

len

[GCinDC]

got any road tires for that puppy? you're needed at sandy hook on may 26...

now gotta ping mwkeefer..

[Lenk42602]

got any road tires for that puppy? you're needed at sandy hook on may 26...

now gotta ping mwkeefer..

I just might make it. Gotta get some days off and some cash in my pocket tho.

After the controller business got sorted, my alloy shell charger set to 86.7v decided to go buh-bye. The toroidal transformer fried - all the coating on the windings burned off, emitting lovely plumes of white smoke in the hall where it was charging. I also melted my power switch contacts on my last ride... Had the switch in line on the main pwer leads, rather than the "ignition switch" lead. Re-wired that tonight..

Fortunately, I bought a cheap ($60) 24s Lifepo4 charger on ebay last fall as a back up - She has been doing the job okay, but I gotta find a better built job if I am going to charge my pack quickly.

I can get away with using SLA chargers set up for 72v, an there are a few out there that seem to be viable. They all seem to charge at ~86 to 88 volts and then float at 81v..

cheap:
http://www.google.com/products/catalog? ... DcQ8wIwAg#

Well Built:
http://www.impactbattery.com/i7212-dual ... 2-amp.html

Kelly, but looks like all the turd chargers that are proving poorly built
http://kellycontroller.com/f7210-72v10a ... p-108.html

gotta find something that isnt crap!

Len

[Lenk42602]

My ride in yesterday am. No music. Bike sounds bad ass enough.



len

[Lenk42602]

.......aaaannnd coming home the same day....



I pulled a nice one this morning - had the bike already to go for the ride in. Dragged it down the steps, helmet, gloves, pack, throw a leg over. Turn on the bike - nuthin. No power. Baffled. Stumped.

As I was running just a bit late, I rolled it into the garage, and threw all my riding gear in with it. Shut the door, hopped in the car. While diriving in and running through possibe reasons, I realized that late last night I pulled the BMS off the pack and checked each cell to make sure all are behaving/balancing as they should.

Well, when you unplug the bms from the cells, but not from the power leads from to he pack, you are telling the bms that all the cells are at 0V....

I uhm, forgot to throw the pack on the charger after last night's cell check to re-power the BMS.

Did so a few minutes ago now that I am home and badda bing.

I don't do well when rushed.....



Len

[auraslip]

All those cars stuck in traffic must be pissed at you

[Lenk42602]

Every day! For some reason they are more pissed when I am on my road bike. Can't quite figure that one out....


Len

[Lenk42602]

Aargh! More issues. Please HALP. Getting frustrated!

viewtopic.php?f=2&t=39186


Len

[XLR8]

Looking very nice! I wish I would have gone that route with my build using the square tube, it makes the fitting SOO much easier and will make for a cool final look! Are you planning to use rivnuts to secure the body panels? Would really make it easy! I got some and I LOVE them for stuff like that... Also, is that one of those rear shocks from a mini dirt bike? I was wondering how they worked for something like this...

Thanks Whip,

Exactly why I used square tube...Easy to keep everything aligned...Haven't yet figured what I am using for the panels, but they will attach at the corner gussetts of the frame. Got a few more miles to go before I get to that stage...

fast ace pit bike shock:
http://cgi.ebay.com/ebaymotors/ws/eBayI ... vi-content

Later,

Len

Hi Len,
I have enjoyed reading your build immensely. I am building my own frame now. So what I would like to know is -
What rear shock did you end up with? The link above no longer exists. Can you tell me the model of the shock and description of the spring? Also, what is the length of the swing arm ( centre of pivot to centre of wheel axle) and the distance between the centre of pivot of the swing arm to centre of rear shock bottom pivot? Buying a rear shock will enable me to finish the project.
Your response would be a great help to me.
Regards,
Kev

[GCinDC]

i've been getting crazy ideas about framebuilding again.. just reread this entire thread. such a great resource! friggin awesome build!

what's become of it?

what are the lessons learned?

how was the rear suspension with the moto shock?

best,

g

[Lenk42602]

i've been getting crazy ideas about framebuilding again.. just reread this entire thread. such a great resource! friggin awesome build!

what's become of it?

what are the lessons learned?

how was the rear suspension with the moto shock?

best,

g

Greg,

I have not ridden the bike since last posting about the capacity issues with the pack back in April. It was determined that at least one cell was bad, but upon opening the pack, there were a quite few more cells in need of replacement than originally anticipated.

I am told that I should be seeing a fully functional pack in the next several weeks.

Over the summer, this dilemma has made it difficult to enjoy the fruits of my labor.

Hopefully I can report once I am on the road again.

I can tell you for sure that moto shock was the right choice for my build, suspension design, and gvw.

If you're building a bike, and you want to make it as exciting as possible, power to weight ratio is key, as is keeping the entire bike light enough that it still feels like a bicycle.

.....otherwise you just have a freaking cool electric dual sport moped that looks like bicycle....

Len

[Emoto]

Lenk nice Evolution
Im building a hub into a 17" mx rim and have a little flat spot/defect.
I noticed in one of your videos your rear rim is not exactly round [has some visible up and down play ] how much is it- 4mm ? and more to the point can you feel it when riding.
Ow and your rear disc rotor where did you get it/model

[Lenk42602]

rear rim is out maybe a few mm. Those moto tires do not come out of the molds perfectly true either. Either way, I didn't notice. the rear rotor is a custom job from a friend in croatia. only reason it is that large is because the hub motor is an old pre-disk 5303 and I had to utilize the cover plate bolt holes for the disc rotor.

Len

[Emoto]

Ok Lenk Thanks, the supplier of my rim said i could return it if needed,mine has the same 2/3mm out of round so ill take a gamble on it.
I also would like a friend like that ,will be hard to find a rotor that fits light and thin enough, the quest moves on.

[Lenk42602]

In a curious coincidence, i am heading out the door right now on the "mid fat" build for its inaugural work commute. I just checked the tracking status for the battery replacement Cellman sent out for the Skill. It is in the postal truck on the way to the house.

So no ebikes all summer, and now I am looking at two runners very soon.

More updates on this one once she's wired up and rolling again...

Len

[Lenk42602]

Soldered a few connectors on the BMS/wiring harness today and got the subpacks back in the bike.
Going to load the controller profile I had on my 18X4110 this spring.

Everything should be neat and tidy in a few hours.

[Ypedal]

to hell with the neat and tidy, put some damn tape on it, get on with the road test, less agrevation if it fails again and you have to un-do all that work

[Lenk42602]

Im back baby. Bike is running again.

Had it up and down the street this afternoon.

May go for a jaunt this week end....

[iovaykind]

Congrats! Long awaited is this comeback!

[Drunkskunk]

Awesome man. Congrats!
your bike and this thread is one of the things that inspired me to build my own frame.

[Lenk42602]

Awesome man. Congrats!
your bike and this thread is one of the things that inspired me to build my own frame.

fellas - thanks.
Planning on heading out saturday to finish that ride I started in january but never finished. I will go pro it up and see what I can put together.

Skunk - I am glad to hear I had an influence on you building your bike. That thing is a beast and just looks bad ass! If we were nearer each other, I would suggest we get together and do a "Masters of Heavy Metal Mayhem Ride" or a "Iron Pile Pile-Up Ride" or something to that effect. Big, heavy, kinda fast, but not super quick wheelie prone - whining rc motor type build...


Its funny - my patience waiting for a new pack turned to apathy,then to disgust. Couldn't look my girl in the eye. Once I rolled her back out into the light, I was reminded of how much heart and soul went into the building of it. Blood was spilled. A metal sliver was removed from my iris (yes I was wearing eye protection, and this bike was the second time it happened) lest I get a rusty eyeball. If you have never felt the discomfort of a metal sliver lodged perpendicularly into the eye, and scraping your inner eyelid on every blink, then you do not know metal like i do...

All of the effort of the creator is imprinted into the machine. Sounds like I'm gettin biblical up in heeyah....

I think that is why certain custom built bikes have the impact they do on others.

Len

[Lenk42602]

MISSION: SUCCESSFUL

So out the door I went:

Total distance 28.3 miles
Ah consumed 13.25ah
Amp Max - 52
Max Speed - 47.3
Watt Hours used - 1025
Wh/Mi - 36.5

Was about 51 degrees today. Ride started from the house, down the long, boring road along the Allegheny River into Pittsburgh. At the end of Allegehny River Boulevard, I shared the same space at a stop light with a full dresser BMW touring bike. Messed a bit with his head when the light turned... made my way down Butler Street into Downtown Pittsburgh. My better half has to work today, and synchronistically, just as I was passing where she works, I spotted her walking down the street. Next up was the Eliza Furnace Trail back out of Pittsburgh along the Monongahela River. This was the section that The Skill broke down on me last january. At the entry point, I passed a couple of guys that we ride with out of the shop. After that, the next hurdle was getting past the exact spot of breakdown. Bad memories. Like a vet going back to 'nam.. Passed, breezed past, the breakdown point with only about 6.5 Ah consumed out of my pack. At the end of the Eliza Furnace trail I hooked up through Schenley Park and the gravel multi use trails. No problem. Then it was back up and into the East End of Pittsburgh, stop for coffee, stop into the shop and vindicate myself to the boyz...After slurping down the coffee, I suited back up and headed for home in the sun. I ran the bike gentle, easy on the throttle,and had the controller max amps set to 45-ish. The first full length shakedown ride without incident. Nearly two years (to the week) since finsihing the build.

This was a zen ride on a good saturday afternoon.



I will be posting a vid later tonight.


Len

[iovaykind]

You know why you haven't received any replies right? We're all waiting to comment on the video!!

[GCinDC]

woohoo! the skill is back! so happy for you! that was a rough couple months there.