First E-Bike build - Full suspension, geared & DD motor

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Lyen 12fet showed up today! Not hooking it up yet. Going to see with the program on the lyen is first. Also got my battery charging finally setup today. Charging at 24v 11a on the hyperion right now.

 

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Refills 8.5 amp hours in 60 minutes on this pack

 

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Been logging some miles on her. Also calculating the mileage vs amp hour use. Right now my dash meter is didital voltage, but I can see how many amp hours the charger puts back in. I'm getting a "feel" for this battery pack, I can tell when its getting spent based on performance.

 

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Further refined the battery box. More slots, velcro, neoprene, and 3m double sided tape. Also installed some catch screws for the box

 

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Been working flawless! Swapped back to black pedals. Battery case mounting is solid and easy enough to remove. Just needs some paint.

 

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Put 100 miles on her since last post. Nothing but good things to say about the amped bikes kit. Been running the controller enclosed in a bag, 20 miles at a time, full throttle and no issues at all (knocks wood). I'm thinking a stronger fork would not hurt and I am constantly jumping and doing wheelies off jumps with this. I can see/feel it flexing. It's only a couple months old right now, but I'm going to be in the market for a DH, double crown VERY soon.

 

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Controller upgrade day. Making the 9fet and 12fet "swappable". I've been using the 9 enclosed and it gets pretty warm. Going to use this nifty cargo rack I found as the mounting holes line up perfectly with lens 12 fet, go figure!

 

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Well I chickened out lol. Its been running really good with the 9fet , I decided to keep it. I did however , relocatd it, lowered the center of gravity, shortened and solidered direct the phase and halls. Also dumped a little solider on thr shunts. I can redo the batt pack to 18s3p, but 12p5p has been working good for range and speed. Just wanted a little more off the line.

 

[Racer_X]

Love this build, your giving me alot of inspiration. Keep up the good work.

 

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Soldered and heat-shrinked phase and hall connections.

 

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Lots of miles going on this bike, its been real nice here! 80's and sunny.

I converted the handlebars to moto-x style and am using a BMX neck. It raises up the handle bars and puts me more upright. Was getting some serious neck/shoulder kinks from extended rides hunched over. Looks like a damn pit bike now lol. I'll have to get some pics up for you guys!

 

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Pics of my new handlebar setup. The bars are for moto-x and are 1/8" wall, about twice the thickness of BMX bars. Changed the neck to a Sunday! brand BMX style. Still running a trusty self powered voltmeter, and honestly it's all I really need to know my "fuel" level. Still on the fence about buying a CA.

 

[sn0wchyld]

very tidy mate. Whats the mount made of/painted with?

I'd still reccomend a CA. its more than just a fuel gauge.

 

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Thx sn0w,

The mount is made from machined aluminum, and I painted it with "wrinkle finish" automotive paint. It's ultra durable, made for valve covers and such. I had to rebend it with the BMX setup, but still works good overall. The blank space is for a GPS unit I have that is not installed yet.

 

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Still running good! Its been 80 at night here. Added gps unit with 3m tape. Survived 25 miles so far and works great. 27 mph is topped out according to gps. Overall has been a nice reliable drivetrain.

 

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I need 50ah!

 

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Sorry about the pics orientation, that's what happens when you ride, gps, pandora, camera, and volt at the same time...

 

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Been running her hard, trails and street. Finally got a flat on the front from a fish hook but fixed it up with a new tube. Current pic "in the woods" Been getting 20 miles with my current setup, ending @ 30% batt life.

 

[kfong]

Joe, looks like you have been riding a lot more than me. I'm working full time now so I have very little free time to ride. I did take my bike out to Tree Farm http://www.trails-edge.com/mtb/mi/novitreefarm/treefarm_main.htm To do some trail riding with a friend Sat. morning. The trails were a blast with some of the biggest log piles I've seen and lots of technical sections. Worth checking out.

 

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Did some serious maintenance on the ebike, Pulled the hub motor for cleaning and inspections, pulled the freewheel for cleaning and greasing, cleaned and oiled all pivot points in the suspension, went through the chain and chain ring (found a bent tooth, explains the occasional chain pop) and gave the entire thing a good cleaning. Installed a new front rim without quick disconnects, i like the standard bolts for this setup, and it matches the rear rim. Installed new "thorn proof" giant tubes, awesome, about 4x thicker than standard, and threw on a pair of knobby tires so I can access more rugged terrain. The knobbies make it a totally different machine, not quite as efficient but the fun factor has doubled! The new tubes and tires also solved a random noise I had at higher speeds when hitting a big bump. Apparently I was hitting the rim, since this new beefy tube/tire combo the noise went away. Lesson learned about tires and tubes!

 

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I know it's been awhile since I posted here but just wanted to say I rebuilt this bike again over winter 12-13. Now running a lyen 12 fet controller on 18s3p lipo arrangement. I also have enabled regen and it is amazing! Since I have regen I scrapped the disk in the rear and went with a V brake setup with koolstop pads for weight savings and simplicity. I am using them with a switch activated rear brake lever that activates regen first then squeeze a little harder and the pads engage. I also had some doc bass torque plates welded to the original torque arms to make sure the axle didn't move with the regen. Went through the hub GOOD over winter and did the I/E vent holes, rust proofed the stator and windings, and upgraded the phase wires to 12g copper. Swapped out the H2 tires for some 2.4" CST cyclops tires, which improved the ride. I think that about covers my newest mods, I posed some pics on endless sphere FB page but need to get some for this thread. The bike is much faster now, tops out at about 33-35mph and gets there quick. I've got to keep an eye on the hub though, she gets hot if i'm dumping lots of current over and over. Ride on

 

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pics

 

[Bike_on]

I read thru your whole build. Great job.

 

[kfong]

Joe how's the batteries holding up? My 15ahr packs are now 10ahrs. Are you doing any trail riding? There doesn't seem much on the east side. You should head up to Stoney Creek, I can take you through the trails there.

 

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Batteries have been holding up great so far, they seem even more efficient in 18s config, when I am not juicing on it. I have not been able to get in as much riding this year due to a baby on the way but I don't think my batteries have lost any capacity to tell you the truth. Granted, I only take them down to 3.5v per cell. I've just been riding paved trails. I love off roading but it destroys the bike too quick requiring more rebuilds / maintenance. So I've kept it *mostly* on road this season. I have an 86 honda 250 ATV to get my off road fix.

-Joe