Specialized Enduro Comp / BMC Build Thread

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oatnet   10 MW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by oatnet » Jul 12 2011 5:14pm

nicobie wrote:Thanks for the link. Exactly what I was looking for.
You'll love them, they are nice and light. :D

-JD
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oatnet   10 MW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by oatnet » Aug 09 2011 8:55pm

Ambrose asked to see inside the battery box, I realized I had other pics I could post of it, so here you go:
IMG_3008_640.JPG
IMG_3013_640.JPG
IMG_3014_640.JPG
IMG_3015_640.JPG
IMG_3016_640.JPG
IMG_3017_640.JPG
IMG_3018_640.JPG
IMG_3020_640.JPG
IMG_3022_640.JPG
IMG_3055_640.JPG
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oatnet   10 MW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by oatnet » Aug 09 2011 9:50pm

Here is the charging setup:
IMG_5181_charger.jpg
IMG_5239 Charging port.jpg
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Re: Specialized Enduro Comp / BMC Build Thread

Post by ambroseliao » Sep 22 2011 1:06pm

It looks like all of the photos are gone. :(

Ambrose
http://www.ebikes.ca/ is the best!

TidalForce M-750X, Tidalforce S-750 with Crystalyte HS3540, 1x TF iO-X Cruiser. E+ 1000W hybrid bike. ebikes.ca DrainBrain & Cycle Analyst meters. GoPro HD Hero2 camera. Bosch Fat Packs, 37V 10Ah LiPO pack. Turnigy Multistar batteries
My blog: http://ebikerider.blogspot.com
Remember LiFEPo4 HVC is 3.65V and LVC is 2.7V

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Re: Specialized Enduro Comp / BMC Build Thread

Post by deepfraught » Sep 29 2011 9:06pm

+1 curious to see the inside of box if the pics can be reposted!
History: Front hub SS 200W, China E-mtb 200W, 3x A2B Metros, Commuter Booster beta, 2.4kW d/s w/DD kit, MAC 1.5kW road/flatbar 1250Wh EM3EV frame batt, BBS02 750W d/s MTB 1250Wh frame batt. All sold (except A2B Metros pending TLC from storage).

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oatnet   10 MW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by oatnet » Oct 01 2011 5:46pm

Hopefully we have seen the end of the disappearing images... I'm gonna keep the original post intact, to see if they ever come back. Here is a repost of the same pics, with the same commentary attached (assuming I got the comments back in the right order!). :D

-JD
IMG_3008_640.JPG
The bottom of the box, where the 8gah wiring exits the box, each to a power switch, which fits into slots I cut into the bottom fins. Note the right side of the photo, the resistor in heatshrink, around the switch. I flip the OTHER switch first, and the resistor lets a the current trickle in to charge the caps in the controller. This avoids a surge at power-on, and gives me a nice way to power up the CA without powering up the full system - to check, or when wheeling the bike out of the garage... When the controller is charged up - a moment or so after the CycleAnalyst boots... Then I close the switch with the resistor, and the system has full current. I originally planned to epoxy the switches in, but the build seems fine as is. The wiring is hidden from side view by the flaps the switches are installed in, and from the frunt by the bottom of the hinges.
IMG_3008_640.JPG (62.99 KiB) Viewed 5443 times
IMG_3013_640.JPG
The box sitting open, the two 8gau wires, wrapped in protective heatshring, terminated in 45a andersons (clamped and soldered) inside the case. You can see the bolts/locknuts/washers I used to secure the case to the clamps. I originally planned (6) clamps for this, but tested the waters with only (4), and it seems solid so I stuck with it. I have no idea what the long vertical object is, sitting on top of the case.
IMG_3013_640.JPG (65.54 KiB) Viewed 5443 times
IMG_3014_640.JPG
A 50a circuit breaker with 8ga and (2) 45a andersons; it will go in the middle of the pack to give maximum protection by dividing the voltage.
IMG_3014_640.JPG (35.17 KiB) Viewed 5443 times
IMG_3015_640.JPG
Here is the first 8s16ah block of cells going in. It is standing up so that you can see the blue heatshrink I put around each anderson connection to keep them in solid contact. On the bottom is red plastic (from the lid of a storage bin we used as a litterbox) that goes over a layer of high-density foam, covering the bolt heads. More of the foam is at the base of the box (top of the picture) and has blue lines watermarking the height of the sub-packs. Note the channels carved in the foam for the power leads.
IMG_3015_640.JPG (55.73 KiB) Viewed 5443 times
IMG_3016_640.JPG
The first sub-pack installed. Note the power lead top left, tucked into place in the foam. the other side of this battery is connected to the circuit breaker, which is wrapped in red heatshrink (bottom right) and tucked into place.
IMG_3016_640.JPG (51.45 KiB) Viewed 5443 times
IMG_3017_640.JPG
Another layer of plastic, with the warning label indicating that this battery box is not a safe place to store babies. Who Knew?
IMG_3017_640.JPG (49.96 KiB) Viewed 5443 times
IMG_3018_640.JPG
The second battery in place, more blue heatshrink overlapping the anderson's' heatshrink, to protect/clamp the connectors.
IMG_3018_640.JPG (67.56 KiB) Viewed 5443 times
IMG_3020_640.JPG
My first go with this motor was 48v, so I only had two 8s sub-packs in there with a big slab of foam. You can see how the wiring can be neatly folded away on the left side.
IMG_3020_640.JPG (64.13 KiB) Viewed 5443 times
IMG_3022_640.JPG
The back of the completed battery. Note the strain relief on the andersons, the clamps, and you can even see one of the power switches hidden away on the bottom of the case.
IMG_3022_640.JPG (88.51 KiB) Viewed 5443 times
IMG_3055_640.JPG
Here I am adding the 4s sub-pack to bring the pack to 60v nominal, or 73v off the charger, and about 67v under load. The lid was easily able to hold all three sub-packs standing on it, this box is strong!
IMG_3055_640.JPG (70.99 KiB) Viewed 5443 times
IMG_5181_charger.jpg
I got a bunch of these Vicor PSUs for really cheap, loaded with (8) 48v4.2ah cards that can be adjusted from 35v to 58v. Here Ihave them configured as 2s4p, which means I could pump 16.2a from 70v to 116v. It would require 240v to supply that much current though, and while this is 120/240v unit I only have 120v.
IMG_5181_charger.jpg (104.5 KiB) Viewed 5443 times
IMG_5239 Charging port.jpg
Here is the charging port on the bike!
IMG_5239 Charging port.jpg (94.3 KiB) Viewed 5443 times
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ambroseliao   100 kW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by ambroseliao » Oct 01 2011 6:42pm

Thanks JD.

Ambrose
http://www.ebikes.ca/ is the best!

TidalForce M-750X, Tidalforce S-750 with Crystalyte HS3540, 1x TF iO-X Cruiser. E+ 1000W hybrid bike. ebikes.ca DrainBrain & Cycle Analyst meters. GoPro HD Hero2 camera. Bosch Fat Packs, 37V 10Ah LiPO pack. Turnigy Multistar batteries
My blog: http://ebikerider.blogspot.com
Remember LiFEPo4 HVC is 3.65V and LVC is 2.7V

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Re: Specialized Enduro Comp / BMC Build Thread

Post by chroot » Oct 06 2011 2:01pm

Nice FS ebike! I wanted see your opinion on Cloud9 seat and I was thinking get 2 of these Cloud9 seat from amazon with free shipping. Is it comforts sitting long trip?

Let me know :)
Thank you Justin Lemire-Elmore - You are a HERO!

Tidalforce, Yuba Mundo V4 Cargo bike, Juiced Riders ODK V1 Cargo bike
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oatnet   10 MW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by oatnet » Oct 07 2011 4:30pm

chroot wrote:Nice FS ebike! I wanted see your opinion on Cloud9 seat and I was thinking get 2 of these Cloud9 seat from amazon with free shipping. Is it comforts sitting long trip?

Let me know :)
Thanks chroot!

I am a big fan of cloud 9 seats, comfortable and durable, they are a standard item for me, and I highly recommend them. When I was planning a line of ebikes using those TF frames I sold here, I bought and tested a good 20 seats to see what suited me. Cloud 9 was the standout product from that test. Note that this is the super-wide comfort version, and not the cheapest brand, but if you've ever permanantly lost a road bike seat in your butt cleavage, this is what you want.

This same testing phase also got me hooked on Ergon grips, On-One 'Mary' handlebars, Dimension adjustable stems, Mirrycle's, and the Thudbuster seatpost. The combination took my rides from painful to comfortable, and I have used them on every build I have done since (except no tbuster on this FS bike). I still have a few seats left from my last order of (10) :lol: I also have a wide "exercise bike" Cloud 9 seat that rocks.

Around the same time, I picked up Maxxis Hookworms, Kenda 2.25mm downhill tubes, and Panaracer kevlar liners from ES 'OG' xyster (who I learned lots from, but he left here about the time cliques started to form). I have not had a flat in 4+ years and some 20k on eBikes.

Later on, I standardized on Alex DX-32 rims, they are a great match for the Maxxis Hookworm, the 38mm rim spreads the hooky into an ideal contact patch.

Way more detail than you asked for, I guess once I get started talking on products I believe in... :oops:

-JD
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Re: Specialized Enduro Comp / BMC Build Thread

Post by chroot » Oct 07 2011 10:18pm

I went ahead ordered the cloud9 seat from amazon. Thanks for the review on the cloud9 seat.
Thank you Justin Lemire-Elmore - You are a HERO!

Tidalforce, Yuba Mundo V4 Cargo bike, Juiced Riders ODK V1 Cargo bike
English is my secondary language - ASL (American Sign Language) is my primary.

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Re: Specialized Enduro Comp / BMC Build Thread

Post by Beavinator » Oct 21 2011 1:38pm

I really like this bike!! Mounting the battery pack to the forks is a smart idea and that bike looks so clean! I hope that you don`t mind if I copy you on my Norco Shore build. I was going to use a backpack but I would much rather keep the Lipo further away from me if possible. :mrgreen:

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oatnet   10 MW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by oatnet » Oct 21 2011 7:48pm

Thanks Beav! :D

You will be pleased by the handling. It took me about a day to get used to the quicker steering, and then I was stunned, it was like I went from a Cessna to an F-15. LiPo or LiFe will get ya there! :lol: With the volume saved with lipo, you would have space up there to mount the controller too. I did that on mrs oatnets bike, just ran 8ga phase wires for the higher motor current.

It isnt all roses of course. It is less stable on a kickstand, I'm hoping the heavy motor in my upcoming build will offset the balance better. Of course, this bike doesnt have a kickstand mount anyhow. Nose weight makes wheelies more complicated, but the rest of the time it keeps the front suspension planted. I've taken 2' drops and was able to bring the nose up, kick off the rear suspension, and nail a two-point landing. Get your mass over the handlebars like you were riding a dirtbike, and it is real easy to kick the back wheel around.

-JD
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153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


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"Cheater?" I'm not competing, I'm Commuting!

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oatnet   10 MW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by oatnet » Dec 04 2011 3:16pm

An enduro comp exactly like mine has come upon feeBay:

http://cgi.ebay.com/ws/eBayISAPI.dll?Vi ... _500wt_922
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Re: Specialized Enduro Comp / BMC Build Thread

Post by gensem » Jan 03 2012 5:54pm

Oatnet,

I went a little bit further and decide to solder the frame. Its a big block coz its aluminium and like to overkill a little.
This is how its looking now (bad quality cel pics)

Image

Image
Justin we really appreciate what you did!

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oatnet   10 MW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by oatnet » Jan 03 2012 6:42pm

gensem wrote:Oatnet,

I went a little bit further and decide to solder the frame. Its a big block coz its aluminium and like to overkill a little.
This is how its looking now (bad quality cel pics)
Nice job, that is going to work out well. I look forward to seeing the box mounted!

-JD
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


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Knowledge is acquired through experience, everything else is just information - Albert Einstein
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veloman   1 GW

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Re: Specialized Enduro Comp / BMC Build Thread

Post by veloman » Jan 04 2012 4:23pm

There's a bunch of these fsr type FS bikes on Austin CL, in the $300 range. I already got my sweet looking fsr and khs as the current ebike. Check my thread to see how I mounted my battery, it JUST fit. Otherwise I was going to do what oatnut die with the battery on the forks.
Mush! Mush you electrons! Push harder!

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Re: Specialized Enduro Comp / BMC Build Thread

Post by gensem » Jan 04 2012 4:40pm

Doc's torque arms with two m5 and DP420 epoxy

Image


Controller tray

Image

I think I should start my own thread :)
Justin we really appreciate what you did!

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