Giant Trance build

General Discussion about electric bicycles.
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kiwiev   10 kW

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Giant Trance build

Post by kiwiev » Mar 22 2015 4:29am

Hi everyone

Newbie here

Starting this backwards have just got bike going this weekend the biggest EV :D

So started build 3 weeks ago with lots of research on this awesome forum.

Bought 2014 Giant Trance frame

Will try and post photos

Cheers Conrad

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 4:43am

[img]
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Photo 9-02-2015 8 56 15 pm.jpg
mocking up battery box not much of a solid works fan like to see it for real

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 4:45am

plan was to fit 22 headway 10 a/h batteries in
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Photo 9-02-2015 8 56 24 pm.jpg
Photo 9-02-2015 8 56 41 pm.jpg

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 4:46am

battery holder on top
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Photo 9-02-2015 9 21 13 pm.jpg

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 4:55am

So I proved I could fit them in :D

Time get the bike looking like a bike Im lucky to live in the Snowy Mountains and 35 km from Thredbo so was really wanting to try it out on the new Thredbo Valley Trail TVT

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:05am

A quick mock up with Crystalyte HS4040 hub motor DNM 200mm air tripple crown forks
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Photo 17-02-2015 3 12 52 pm.jpg
starting to look like a bike

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:07am

this was the hardest thing to do cut up a perfect frame :twisted:

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:10am

not much inside :)
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Photo 25-02-2015 3 31 18 pm.jpg

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ridethelightning   1 MW

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Re: Giant Trance build

Post by ridethelightning » Mar 22 2015 5:13am

coming along!
id ditch the headways though, much better to go with 18650 for compactness

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:13am

made battery box out of 3 mm aluminum tried folding but too thick so i run a 1-2 mm cut on inside and then folded. this melted folds with TIG to bond again.
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Photo 25-02-2015 3 31 35 pm.jpg

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:17am

I had the Headways for a EV car so had them for that but went bigger :)
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Photo 13-12-2014 7 38 59 pm - Copy.jpg
EV sonic

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:20am

So after I made the box I managed to cram 22 headway's in. And in my eager excitement almost blew the box apart i never took a link out or taped terminals would have been nice having 70 volts short :mrgreen:
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Photo 11-03-2015 5 39 25 pm (1).jpg
after I took link out

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:27am

A mate and I TIG box in came up pretty good :)
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Photo 28-02-2015 4 04 41 pm.jpg
Box TIG welded in

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:30am

So it was off to Sacred Ride our local shop to put cranks 6 speed cluster and 200mm disc brakes and 2twin pot calipers.
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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:39am

I used a smaller rear disc to space out 200mm disc to line up with caliper.

The seat post is a DNM dropper they seam to be OK for half the price.
The 22 headway have a BMW to each cell monitoring high and low voltage thru a simple close circuit loop for high and low.

So the ignition wire from the Lyne 18 FET controller go thru this loop to pack voltage and back via handle bar on off switch, so if a cell drops it will trip the loop and kill the ignition.

The same applies to the high voltage loop which holds the 72 volt 20 amp charger on.

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 5:54am

Next step was to make torque arms mtbe fro Melbourne sent 2 6mm by 50 generic stainless arms I ordered 2 more to give 12mm each side after searching threads here I thought of trying something different and more KISS in principle have 60km on it now with no problems.

Like your thoughts please.

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 6:06am

have to paint yet was waiting to see if they survived the weekend which they did :P
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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 6:07am

another angle same torque arm for de-railer side too.
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Photo 22-03-2015 9 58 36 pm.jpg

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 6:08am

this was Fridays maiden ride WOW WOW :P
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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 6:21am

If I did it again I would have made battery box deeper to hide controller wires, I did manage to duct rear brake line and derailer cable in box.

So first run was great Lyne is great plug and play controller and worked first time straight into CA. The 3 speed switch is a must. The first ride down our driveway and straight up to 70kph on switch 3 at 3.9kw not bad.

Place bike on bathroom scales 29.7kg I'm not sure if this is good or bad.

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ridethelightning   1 MW

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Re: Giant Trance build

Post by ridethelightning » Mar 22 2015 6:26am

torque arms look good in principle, but it depends on how tight the tolerence is where it contacts the axle flats. i would have considered making it extend back a little and put a bolt through to clamp it.


looking really nice though!

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 22 2015 6:40am

I did take a photo of torque arms prior to welding they are a laser cut hex slot that fits tight inside the outer arm.

I did think about extending back more the arm is 10mm thick and about 65mm long, I was worried about drilling hole thru swing arm structure.

The ny-lock nuts hold the arms over the swing arm.

There isn't any movement when stall torque the hub again arms.

I wish I could of laser cut some drop outs but nothing relay to bolt to.

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 24 2015 3:46am

Thru the chain a couple of times over the weekend so bought a chain guide roller will instal tonight.

Also installed a E brake handle to operate regen how does everyone else do this?

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 25 2015 4:43am

Went for a ride from bullocks flat to Thredbo uphill and back to try and work out range.

I think I blist Strarva times 45 min for the run about 17km that will annoy the mtb boy's

Gave one of the Thredbo boy's a wee ride I think he suck a bit of power.

I jumped back on to ride back and about 4km in the bms started to switch controller off about t 13.8 wh of use.

So I pedaled for about 13km I was stuffed. :shock:

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kiwiev   10 kW

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Re: Giant Trance build

Post by kiwiev » Mar 31 2015 5:12am

Pump 250 psi in rear shock much better. The DNM front shocks are awesome l was worried they would flex to much but all good. This bike was designed for trails and wow it does it good. The rear derailer rattles a bit wish shimano would make a 6 speed clutch derailer.

So I'm thinking of buying the Kross frame are they good?

Also is anyone making 84 volt 20 ah in Aussie with 18640s with bmw and charger.

The thing I like about the bike I have now is I plug in 72 volt 20 amp charger and it's charged in 30 minutes.

Like everyone thoughts

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