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Laz's first build!

lazarus2405

10 kW
Joined
Sep 5, 2007
Messages
782
Location
Rochester, NY
Howdy folks!

I took a break from ebike dreams back near the start of November, and now I'm ready to get down to building. I'm ordering everything in about a week from today, and I hope to be riding before the Super Tuesday primaries!

The donor bike is a basic steel unsuspended off-road bike, riding on Continental Town & Country tires - medium width, puncture-resistant, and very slick with knobs on the outside in case I encounter mud. I've had the brakes beefed up and I'm adding a suspended seatpost to try to take the edge off cracks in the pavement. I'll be equipping it with an X5304 in the rear. For the controller, I'm having Bob Mcree modify a new c-lyte 72v40a unit, replacing the FETs with IRFB4110s, adding brass bus bars, and installing a twist pot for a maximum current limit of 75a. I'll be powering it with 84v 9Ah E-molis (LiMn chemistry), in 21s3p. I won't be making a custom pack, but rather just using stock Milwaukee 28v packs and bypassing the BMS for discharging. Three Milwaukee 1-hour charging units will round out the build, allowing me to fully charge in three hours (using the BMS, of course).

I'll be riding in town, on pavement almost exclusively, for commuting and much fun. The setup is clearly overkill; by my math, it takes exactly two Milwaukee 28v packs for a full commute to Wal-Mart, even at 30mph. It'll easily be the fastest electric vehicle on the OU campus, with 6.3kW pushing barely 200lbs

So, at the moment, this thread is a placeholder, to help me contain my excitement. My hands are tied until the funds work their way through paper mail (people use that still, it seems), so I'll channel my enthusiasm here. Here's what this thread's near future holds:

Comprehensive pics of the donor bike and tires today-ish.
Delivery in ~1.5 weeks: Expect much Fed-Ex pornography when the batteries, chargers, motor, and CycleAnalyst arrive. Battery modification and mounting to follow.
Approx 2.5 weeks out: pics of the modified controller and the first power. Shortly after, glorious pics of the finished bike and the first testing. Expect large E-Bike Grin.

As a member of the community (and a recipient of a lot of help), it is my responsibility to keep you appraised as another formally enters the fold. A big thanks goes out to Xyster, Fechter, Ypedal, TylerDurdan, and many others for the help in the newbie stages.

Cheers!
Aaron

Update:
Blast, foiled again! I was planning on ordering today, but it is not to be. Instead of electronic transfer, I was informed that "the check in in the mail!". Well, the above plans are now correctly edited to reflect a one week delay. Ho hum.
 
Goin' right for the throat eh? My kinda guy :twisted:

Yep, I bet nobody on campus will beat you in a race. Just remember those torque arms and tighten those axle nuts!

We'll be looking for the pics and reports.
 
Well, I remember back in August when I was planning on a 400 and some SLAs, but (thankfully) worse judgment intervened. :twisted: Frankly, I blame you, Xy, and Lowell.

I've already challenged my roommate to a drag. He's a Mech-E gearhead and has a >330hp rebuilt V8 '72 Ford truck. First one to 20! It should be cake.

Roger on the bolts. Negative on the torque arms, which I remembered only an hour ago that I had neglected. I haven't the means or skill to fabricate them. Any suggestions?
 
Hi Laz,

nice setup coming should be way quick, be careful :)
would suggest getting them made at a machine shop - thats a LOT of power to lay down,i'd want solid arms both sides.

cheers

D
 
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