Peter Sternersson
100 W
Since there isn´t any real suiting swedish forum for electric bicycles, I thought that I would present my ongoing build here instead, for the best support and knowledge, cause this is a goldmine of awesome builds and sweet caracters.
Mind you, I do not write in english every day, so spelling mishaps will occur.
After completing a commuter build last year with a KTM bike, 16S LiFe 15Ah, 1000W hubmotor, and riding it to and from work last fall, I decided that I wanted something more powerful, and something able to climb rocks and trails in the nearby woods.
I got my hands on a used Kona Stab Deluxe 2003(?) from the swedish equivalent to Craigs list.
It came with a Marzocchi Bomber Monster 03 front fork, and some Hayes Nine hydraulic disc brakes with 203mm discs.
It looked something like this (not my bike in the picture, but looks the same apart from the color of the rims).
A short summary of the build is as follows:
Frame: Kona stab deluxe
Tyres: Maxxis Hookworm 26" 2" wide
Motor: Cromotor ver 2
Controller: Lyen 24FET with some beefed up traces for 110-120Amps
Batteries: Haiyen LiPos 20S4P = 74Vnom and 20Ah. They are hardcase 4S so the mounting should be very compact and tough
BMS: Signalab 20S 30A (I will only run charging and the "on" voltage to the controller through the BMS so the 30A limit is not the limit of the system)
Charger: Bulk charging with a 600W BMS-battery alloy charger. Might go ahead and buy a Mastech 100V 10A power supply later on
A very nice feature on the Kona Stab is that the dropouts are removable, so I went ahead and drawn up some new dropouts with good clamping ability around the axle.
I got some help with CNC machining from a friend, and it fits in the frame like a glove!
It also fits really snug around the axle. Almost no need to clamp it actually.
I want the possibility for a powerful regen to save brakes, so I beefed up the rear swing arm with some 3mm stainless steel.
Also welded a 3mm piece of steel for the brake caliper.
I had some problems with the chain on my new BMX freewheel, it would come of when power to the pedals was applied. I was convinced it had something to do with the Shimano chain tensioner that I had modified for the wider chain. So I machined out a new arm and a guide wheel.
Turned out that the chain tensioner had nothing to do with my problem, and the real culprit was the cheap chineese freewheel that had very sharp edges on the teeth so the chain climbed. Some grinding later and it was smooth as a babys bottom.
This is more or less how it stands today. With some luck I´m getting the 20pcs of Lipo from Haiyen today. That would mean that I have the entire easter holiday to build a batterybox, somewhere on the bike
The controller is so large that I´m thinking of putting it on the luggage carrier on the back. You can see the cardboard mock up on the picture. The 24FET is a monster!
Mind you, I do not write in english every day, so spelling mishaps will occur.
After completing a commuter build last year with a KTM bike, 16S LiFe 15Ah, 1000W hubmotor, and riding it to and from work last fall, I decided that I wanted something more powerful, and something able to climb rocks and trails in the nearby woods.
I got my hands on a used Kona Stab Deluxe 2003(?) from the swedish equivalent to Craigs list.
It came with a Marzocchi Bomber Monster 03 front fork, and some Hayes Nine hydraulic disc brakes with 203mm discs.
It looked something like this (not my bike in the picture, but looks the same apart from the color of the rims).
A short summary of the build is as follows:
Frame: Kona stab deluxe
Tyres: Maxxis Hookworm 26" 2" wide
Motor: Cromotor ver 2
Controller: Lyen 24FET with some beefed up traces for 110-120Amps
Batteries: Haiyen LiPos 20S4P = 74Vnom and 20Ah. They are hardcase 4S so the mounting should be very compact and tough
BMS: Signalab 20S 30A (I will only run charging and the "on" voltage to the controller through the BMS so the 30A limit is not the limit of the system)
Charger: Bulk charging with a 600W BMS-battery alloy charger. Might go ahead and buy a Mastech 100V 10A power supply later on
A very nice feature on the Kona Stab is that the dropouts are removable, so I went ahead and drawn up some new dropouts with good clamping ability around the axle.
I got some help with CNC machining from a friend, and it fits in the frame like a glove!
It also fits really snug around the axle. Almost no need to clamp it actually.
I want the possibility for a powerful regen to save brakes, so I beefed up the rear swing arm with some 3mm stainless steel.
Also welded a 3mm piece of steel for the brake caliper.
I had some problems with the chain on my new BMX freewheel, it would come of when power to the pedals was applied. I was convinced it had something to do with the Shimano chain tensioner that I had modified for the wider chain. So I machined out a new arm and a guide wheel.
Turned out that the chain tensioner had nothing to do with my problem, and the real culprit was the cheap chineese freewheel that had very sharp edges on the teeth so the chain climbed. Some grinding later and it was smooth as a babys bottom.
This is more or less how it stands today. With some luck I´m getting the 20pcs of Lipo from Haiyen today. That would mean that I have the entire easter holiday to build a batterybox, somewhere on the bike
The controller is so large that I´m thinking of putting it on the luggage carrier on the back. You can see the cardboard mock up on the picture. The 24FET is a monster!