Sinister R9

Hi,

I recently had my bike stolen after 5 years of building and tinkering, 24 September 2019, Perth Western Australia.

It was in the best "tune" I had been able to get and I really loved riding it, I have so very few pictures and determined to remedy that with this build.

This is the "original beast" for reference, I'll post in the stolen section as well.

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I did get insurance but it was one hell of a battle and I'll post some more on that in the stolen section, enough to say I have budget for a new build, while the summer is flying by.....

I really don't like the look of the latest generation of high power bike frames.

I really wanted a unique frame for my build and I found a "Sinister R9" in our local "Gumtree" for sale. This is a high end pure Downhill Racer from the 2000's designed/built by a guy called "Frank the Welder", I've linked to his web site. The company is no longer but the guy still does custom builds and for my opinion this is art crossed with a battle tank.


https://www.pinkbike.com/news/Sinister-R9-Bike-Test.html

http://www.frankthewelder.com








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I started with the intention of a modest, "simple" build. Things have started to go awry, for the money I have spent already I could have had a Surron, I am questioning my judgement, that's not going to help get it done though.

This R9 has had a really "hard" life and I think it's been left in the weather, I have had to replace all the suspension bearings, rear shock, headset bearings and front shocks.

To date the build components are as follows.

MXUS 3K on 135mm dropouts, 14mm shaft, in a 17inch by 1.6 rim with 225-17 M45 Michelin 4T (Should have gone the 3T and 1.4 rim)

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The back rim is 10G and has been built in China by a seller called suringmax Official Store and I do highly recommend him, things haven't progressed as fast as I would like but it is a custom build and he has always been responsive to communication.


https://suringmax.aliexpress.com/store/1514220?spm=a2g0s.9042311.0.0.27424c4dWPdaJV


I'm doing the front in 13G with the washers

ERD is 415mm

Spoke length on the front is 194mm 13G 3 cross.


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59mm



45mm

https://www.aliexpress.com/item/32887090011.html?spm=a2g0o.cart.0.0.775b3c00Kbsu34&mp=1

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I'll try to post links to all the components used, half the battle is finding it and then getting a seller that will use e-packet delievery to Australia. I have spend at least 100 hours finding the stuff.

Still waiting on a lot to arrive.





Alot more to come

Paul

This bike will be EVIL when finished!

Batteries have been an ongoing dilemma , I didn't want the bike to be as heavy as the old one and I didn't like the look of what I did last time.

https://www.reddit.com/r/electronic_cigarette/comments/ba2gli/bench_retest_results_molicel_p26a_2600mah/

I ordered 120cells from

https://liionwholesale.com/collections/batteries/products/molicel-npe-p26a-35a-2600mah-flat-top-18650-battery-authorized-distributor-inr-18650-p26a?variant=16132682154078


I started with 2x 20S3P in this configuration.

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They are 60Amp BMS each, both have RS485 and UART interfaces, 8 Gauge wire, I've made a custom opto isolated arduino board which I will talk about later.

Sufficient to say I'm getting battery data, individual cell voltage, current state of charge, temperature and reliable on/off comms to multiple boards that are optically isolated using the code from the awesome work these guys have already done.

https://endless-sphere.com/forums/viewtopic.php?f=14&t=91672

https://www.endless-sphere.com/forums/viewtopic.php?f=14&t=94522

https://www.aliexpress.com/item/4000019046206.html?spm=a2g0s.9042311.0.0.27424c4dNbF52y

https://www.aliexpress.com/item/32838801202.html?spm=a2g0s.9042311.0.0.27424c4dNbF52y

https://www.aliexpress.com/snapshot/0.html?spm=a2g0s.9042311.0.0.27424c4dytqbtK&orderId=8007507684381903&productId=33014336195

Then I decided I couldn't mount them on the bike the way I wanted without messing up the look....

Not too keen on 2x high powered packs in plastic external to the frame between my legs.

I have 2 cases for sale if anyone is interested, Perth Western Australia.

So now I'm going for 2x 20S2P in an 80mm x 40mm x 3mm, 2.5mm radiused aluminium extrusion. The intention is these will follow the bottom tube and I will cut the top angle of the forks in, aka F14 TomCat intake duct.

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Interested in recommendations on insulating material.

I'm still building the packs then I discovered 21700 cells, the power density and cost efficiency is substantial.

https://www.electricbike.com/new-21700-cells/

https://www.reddit.com/r/electronic_cigarette/comments/b6uyok/bench_retest_results_molicel_p42a_4000mah/

The same chemistry from the same manufacturer is about 25% cheaper per watt hour.

120 x Molicel INR-18650-P26A: $5.24 USD

80 x MOLICEL/NPE INR-21700-P42A 45A 4200MAH FLAT TOP 21700 BATTERY: $6.88 USD

This is from Battery Bro, shipping to Perth Western Australia was around $80USD from Hong Kong for both specs as opposed the $350USD for DHL from LIION in Phoenixville, Pennsylvania. I would use LIION if I was in the States but for my location it is Battery Bro.

Both appear to be reputable suppliers of authentic cells.

DHL really screwed up the shipment of 18650 cells from Liion, it went via USA, HK, China, Korea, Japan then Sydney, which is 5000km away, then overland.

https://batterybro.com

Then I discovered the KWeld, Oh Sh*t I've just spent another $2000Aud that wasn't in the budget.....

https://endless-sphere.com/forums/viewtopic.php?f=14&t=89039

It arrives tomorrow, I'll post more about that later but here is the same pack modelled 20S2P in 21700.

The difference between the 2 pack specs combined is 72V 10.4ah vs 72V 16.8ah and it's not that much longer.

18650 is 34mmx488mm, 21700 is 44mmx536mm

I'm using 2mm spacing between the cells on 18650 to get it into a 40mmX80mmx3mm wall aluminium extrusion.

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So much more to come. I'm still catching up with the story so far....

Paul

Interesting build. Looking forward to seeing more progress. :thumb:

Rear shock mounts are done.

Waiting for the Aluminium supplier to open after New Years for the battery case.

Waiting for the machining to be complete on the rear drop outs.

Waiting for the MXUS (DHL HK is crap).

Paying $10 a day for parking and the weather is sensational riding.

Waiting....

Friday night, long week. Welding and machining of the dropouts is complete. I finished replacing the suspension bearings and headset bearings with NSK's. Changed all the suspension bolts to Stainless. I made a stainless plate to go in the head tube to replace the old bearing. Sharpened the edges, pushed it side ways under the bearing and I was able to tap it out.

I used heat on the suspension components.

https://www.microbluebearings.com/bearing-removal/

http://www.southwestairsports.com/ppgtechinfo/top80/hrservicenotes/bearing_replacement/bearing_replacement.htm

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I received the wheel truing stand.

This is a 19x 1.85 wheel I built up and never used. I went down the bike shop to get a tyre and I could'nt find anything under 5kg. So I never finished truing / building the wheel. It's true it's finished and it's for sale. Excel Notako Rim, 13G Stainless Sapim Spokes and dual disk hub on 20mm through axle.

Still waiting on the new rim and spokes from China, it's sitting in DHL HongKong since Thursday night, 4 hours flight.I could have built it this weekend......

This guy knows how to build wheels.

https://www.youtube.com/watch?v=p2jTrJYJGd8

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Stuff arrived.

I'm now told there is no such thing as a 14mm shaft on 135mm dropouts, only 16mm.

Back to the machinist, actually I think it is going to be the die grinder....

I should have built my own wheel in 12Gauge, I think I might order the spokes. It would have been alot better if everything arrived in the Holidays.

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I actually think the wheels are better built with the washers, especially at high spoke angles.

Don't use 19x1.85 rims they are massive.

I like the 17x1.6 I would prefer the 17x1.4 and I am keen on looking into the 21x1.6 because of the tyres available.

flashtel said:

I'm now told there is no such thing as a 14mm shaft on 135mm dropouts, only 16mm.

Click to expand...

fwiw: that might be true of that particular motor's axle (and various other high power hubmotors), but it's not true of all 135mm hubmotors.

So busy...

No time for words, it is comming together....

Wheel Builds, mounting motorcycle tyres comes with it's own challenges.

any updates?

Alots been going on.

In summary.

Dual front Tektro brakes are installed.

Changed out Sabvoton 72150 with a 96120 and I have 2x 30S boards and a charger that tops at 126VDC

Found a takasago excel 21x1.6 on Amazon for $120 AUD delivered, then found a secondhand one for $40 AUD.

Custom wiring is almost complete.

Had to replace the battery cans with 125mm x 50mm x 3mm extrusion hollow. (That's the sweet spot), I had 7 goes at the Controller mount. It's exactly where I want it to be and I made the minimal mods to the frame.

Paul

Some more Pics, I should take more of the wiring techniques I'm using.

The USD8-A for leaked on one spring chamber (same side as the preload chamber), I returned it and you see the older USD8-S from shocks on there.

The new style and old style USD8 is completely different. Calliper locations are lower (New brake lines), triple clamps have more offset on the newer and wider stanchion centres (just enough so they won't fit). Different bottom axle on later (no threaded end on the later, better).

Kinda wished I had just got the newer style again but I do like the gold.

first thing I noticed was the gold chain, then you said you liked the gold. dual hydraulic front disc,holy crap you are going all out eh.
you said you swapped out the 72150 for a 96120, so I went to see if you changed the battery but the bms is 20s 60amp and you have 2 batteries in parallel for 120amps. why did you switch controllers? ive no clue, that's why im asking

Oh, that's just the INR-21700-P42A pack you can see and only one.

There are two of those, 60amp a piece for 72V 20S2P at 120amp combined sustained (80cells) , load tested and FLIR imaged for hot spots.

They were supposed to go in the 100mmx50mm cans when they didn't fit I had to go 125mmx50mm cans.

Then I realised I had room to use the 120x Molicel/NPE INR-18650-P26A 35A 2600mAh I bought earlier in 2 packs of 30S2P. for 108VDC at 120amp sustained.

I've made a custom opto isolated arduino board to control it all, I'll post some pics of that latter.

So anyways, I'm concerned about motor heat.

Not much range in the 2x 30S2P configuration but it should haul arse.

I'd be interested in predictions a 4T 17inch rim for 100kg all up weight at 1123w/h (have I done the math) for speed and range.

Anyone?

don't know if you've seen this thread on ferrofluid, heat and the epoxies used
https://endless-sphere.com/forums/viewtopic.php?f=30&t=105300

30x3.6=108, 108x10.4=1123wh is the 30p, ill take a wild guess 50wh/km 22km range and a top speed run might melt the motor
id be too scared to try, awesome build

Cool Build

do you know the O.D. of the P42a?

Any updates on speed?