Custom Battery Cyclone 3000 Downhill Bike

KaiKall

1 mW
Joined
Jul 29, 2017
Messages
10
Location
Toronto, Canada
This has been in the works for quite a while now. I still have a bunch to do but the bike is finally in working order.
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This is the first big ride i have done so far, went 65km using just over 1100Wh, the bike is much easier to pedal than i expected.
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Specs:
2008 Kona Stinky Downhill Bike Frame
Cyclone 3000w mid-drive
Kelly KBS72121X controller on custom aluminum heatsink
Custom 72V 21ah pack made from ncr18650ga cells
80A BMS
12V DC-DC converter for lights and acc.
Cycle Satiator for charging
Maxxis Holy Roller tires (these are great so far)

The battery box is made of polycarbonate sheets solvent welded together. The side panels are held on with the through bolts. I originally made the box with epoxy, but a few of the panels become loose just in test fitting. Had to tear apart and redo the whole box.
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Batteries are held by 3D printed spacers. I was originally going to do a compression connections for the battery, similar to this: https://endless-sphere.com/forums/viewtopic.php?t=57810 but due to the bolt spacing I couldn't get even pressure and not all the cells made connection.
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After a few goes i scrapped the idea on this bike and had the pack spot welded instead. I may try on a future battery with a more regular shape.
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Made custom mounting for the cyclone to increase the ground clearance and to minimize the flexing with the stock bracket. 3D printed Chain guard.
View attachment 20220502_171229.jpg
The panel on the other side of the bike I am still figuring out what to do design wise, maybe something with back lighting, but for now it just has a sheet of vinyl on the inside.
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Had to cover up the wire mess to ride in the city, don't want the bomb squad called! :roll:
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This is now my primary transportation and now has its own parking spot in my apartment.
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Things still to do on the bike:
Make a custom rack and fenders
Bash guard for the motor, kickstand both to attach to the motor mounting brackets.
Side panel design/lighting
Ordered a new crank freewheel as the stock seems loose after only 200km.
Motorcycle Dashcam? -not sure if its needed.

This site is responsible for all the work that went into this project and I could not have done it without all the knowledge here. I want to do the same so any questions about the bike I will try to answer.
 
Nice work, K, your's is one crafty disguised hard wired creation.
What's the gross weight bike & pilot? Which rear shock?
Composite fenders?
 
Thanks,

Bike is 80lb and i am about 200. The rear shock is a roco, came with the bike when i bought it. I had to dial the pre-load up quite a bit as the suspension is super soft when setup for downhill.

I want to make some fenders out of sheet metal and weld it to a custom rack as one piece, going to start with a cardboard mock-up and go from there. If i cant get my welding buddy to help i may go fibreglass.
 
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