Fatbike with 2500w Bafang G510 Ultra max

Hi !

My fatbike build have started, and i’m planing to post the process to working bike.

I starded with a frame i got used, sanded and painted it.

The frame came from this bike:


Used bedliner paint


Paint job went very well


Painted feontfenders to

Back fender is plastic


Motor i have orderd from Innotrace in Germany, that is the developer and supplier to wattwagon that offer the 2500w version, Innotrace have upgraded version of this controller that gives 3500w of power with 52v80Amp controller


A callange is battery, and orderd the biggest downtube battery case on the marked. Polly with room for 91 cells


Have found a drawing of fiting 98 cells in this battery case, that means 14s7p 98cells and are going ro use a 50A BMS. Do not think i will be other then some second above 50A and peak A is 120A so i think i’ll be fine.


Daly BMS


Not 100% sure, but looks like it will be Samsung 18650 30Q cells i will use. And if i can fit 98cells in 7p i will have a battery with 52v21Ah


As i wait for motor and rest of the part i have startet to fit some parts. Today i’m fiting backfender.


Found some prefabricated holes, proberly for draining the frame tube pipes. Was perfect for mounting the fender after treading the holes with M5



Front suspension i desided on trying the upside down design as DNM US6 15x150mm thru axl.

I struggled to find a suspension fork with 15x150mm for strait frame tube, only tapperd fork was availble for fatbike. Solution was a semi integretad head bearing.




The head bearing set is in place.


Trying on the front wheel, think it’s looks good

Found the wheels at XXL with reflecting rim tape, 90 mm thru axel 15x150mm front and 12x190mm rear


Fitting a seatpost with suspesion, simpel and cheap but a sweet extra on a hardtail

With the frontsuspension it’s a bit problematic to mount it. Found a cheap extender bolt for the head tube with a mounting bracket.


Need to find some rings for the suspension arms to screw the suspesion rod’s from the fender.

And with the frontlight mounted on the bracket it looks clean


As the Innotrace controller dont have light support, the solution was a Supernova E3. With this frontlight i can run power directly feom the battery (12-60v) with a line out 6v to rearlight and a on/off push button.

The big polly battery case arrived today

Fenders look really good. Where did you buy them?

Hi !

The fenders i had to order feom the uk.

The big polly battery case

Not much more room, fits perfect



Today the cells arrived. The prodjekt i starting to come together



Very positiv test of the 30Q cell
https://lygte-info.dk/review/batteries2012/Samsung%20INR18650-30Q%203000mAh%20(Pink)%20UK.html


Starting to mount breaks and gear on the bike.
For breaking i have desided on Shimano 203mm breakdisk front and rear.


And 4 piston break calipre.


You find more expensive breaks but i hope these will do the job.

Break levers i use Shimano Deore with mount for a SLX 10speed shifter.


The controller from Innotrace do not have out put for front and rear light, so i try connect some lights i found on aliexpress.

First i try to find a place for the DC-DC step down and fuse.


And i need a switch


For front light i use a Led light in a aluminium casing


Rear light i will use a led strip on both side of the rear wheel


Still waiting for motor and battery, and it will take 2-3 weeks before every thing is here.

But some small parts and nick nack lands in the mailbox from china


Just days away the battery pack’s are soon ready, went for one with Samsung 30Q and one with LG MJ1 cells

Everything is now togather and the bike rides like a dream

And the power i can’t be more impressed, Innotrace with the controller has turned this motor from a beast to a monster

I ordered the same battery case to build a 14s 98 cells pack as well. Followed.

Have seen a couple of drawing of 98cell version, but fitting a 60+A BMS as well seems difficult.

Would love seeing your solution

Hey guys, I'm that person, who designed the layout. Haven't got time to 3D-print the parts yet and test fit everything. Going to give feedback and publish the whole design soon.
https://photos.app.goo.gl/zHAfkTd9oUuBhV2t8

For the BMS, I use this chinese Smart BMS with BT and replace the MOSFETS and shunts to easily achieve 60A, while having a max height of 10mm. Excited to see how this works out.

I'm using VTC6 and discharge with a max of 50A. Having 7P, each cell won't reach more than ~7A. This keeps the cells temperature pretty low. Check the discharge/temperature chart, of the cell you're planning to use. Otherwise stay safe and build an 14S6P or 13S7P.

I’m sorry not credit your design, i will of course delete the drawing from the post if you prefere ?

Or you can ad to this tread with your battery build and progress fit 14s7p in the big polly case ?

No bad intesion using your design, just impressed bye the creativety

Tomblarom said:

Hey guys, I'm that person, who designed the layout. Haven't got time to 3D-print the parts yet and test fit everything. Going to give feedback and publish the whole design soon.
https://photos.app.goo.gl/zHAfkTd9oUuBhV2t8

For the BMS, I use this chinese Smart BMS with BT and replace the MOSFETS and shunts to easily achieve 60A, while having a max height of 10mm. Excited to see how this works out.

I'm using VTC6 and discharge with a max of 50A. Having 7P, each cell won't reach more than ~7A. This keeps the cells temperature pretty low. Check the discharge/temperature chart, of the cell you're planning to use. Otherwise stay safe and build an 14S6P or 13S7P.

Click to expand...

Please do post the 3d printed spacers when it’s done. I got my case in the mail today and itching to get it assembled.

I added pictures to the Google photos album. Have a look! It was simply not enough space... my 3D printer was not precise enough and my cells had 18,3mm diameter. Maybe you are able to bring this to work

EDIT: Published my designs. https://www.thingiverse.com/thing:4627055

Editted:

How's progress Sinhu ? any ride videos or updated pics?

Sinhu said:

Have seen a couple of drawing of 98cell version, but fitting a 60+A BMS as well seems difficult.

Would love seeing your solution

Click to expand...

Couldn’t make it fit so I configure it 13s7p. Very tight fit though even at 13s.