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  1. RustyKipper

    Ammo box battery with solar charging

    OK, I thought I might you might like to see my latest battery on my commuter hack, this is the 4th battery in just under 40,000 miles. The last battery looked good but was a PITA from day one as it wouldn’t keep balance for more than a couple of weeks and very nearly caught fire when balance...
  2. RustyKipper

    2WD in snow

    OK, I took my special winter 2WD (2 x 250W hubbies) with studded tyres on the 14 mile trek to work this morning only to find it hopeless in the snow, it was about 5 inches deep :shock: there was absolutely no steering, coming home the roads were sheet ice and the grip was out of this world, it...
  3. RustyKipper

    25000 mile club

    Hey all, I've made it to the 25,000 miles club!!! These are not your Sunday morning pleasure miles, oh no, these are hard fought white knuckle rush hour day in day out commuting miles, the UK is a bit of an insane place to do a daily extreme commute as it is hellishly busy at the best of times...
  4. RustyKipper

    hardcore commuter now in the 20K mile club

    Hey all, I've just joined the 20,000 mile club with my hardcore commuter!!! This bike does a round trip of 25 miles per day in all weathers with a ferocious 30mph howling gale from the pennine range on the way in and an 800 foot uphill slog on the way home. The terrain is everything from fast...
  5. RustyKipper

    Solid tires?

    Hey all, I'm having a bit of a time trying to keep the wind from escaping from my tires. I'm running Swarble marathon mondials with ultra thick alpine thorn resistant tubes (about 3mm thick), I have a 28 mile per day commute to an industrial city and back in the North of England, the roads are...
  6. RustyKipper

    Beefing to reduce fork flex

    Hey guys, My daily commuter suffers from pretty bad fork flex ie. if I waggle the handle bars quickly or hit a pothole I can build up a fair bit of death wobble, although it doesn't continue it doesn't inspire confidence and makes the bike feel like a blancmange! I think this is mainly due to...
  7. RustyKipper

    15000 miles today

    Hey all, I hit 15,000 miles today in 3 years Woohoo! :D Here is what it took: 9 chains (they are badly stretched after 3 months, these are difficult to keep lubricated as it often rains so the oil gets washed out and road grit gets washed in) 6 cassettes (wear) 4 chain wheels (wear) 1...
  8. RustyKipper

    Ice bike commute UK

    Hey all, I have a 14 mile each way commute to work in South Yorkshire which I've now done for 3 years, this is right out in the sticks and over some quite high passes and VERY hilly, however for the colder months I've put together a purpose built E-ice bike. 250W motor in the front wheel...
  9. RustyKipper

    Bafang CST freehub removal

    Hey guys, As per the tittle I need to service the freehub on my 500W CST hub. It goes through spates of slipping really badly which is a bit worrying as if it fails completely I have a 5 hour walk home from work, or if crossing a freeway I will come to a sticky end. If I spray penetrating oil...
  10. RustyKipper

    Brake upgrade for hard commuting

    Hey guys, I have a brutal 14 mile each way commute between 2 city’s, the terrain is very hilly often freewheeling at well over 30 MPH and then braking to a stop at the bottom for junctions etc. City riding is in the mid-twenties with constant braking to avoid potholes, debris, cars, zombies ...
  11. RustyKipper

    Interesting fact of the day

    OK guys, todays interesting fact. As I commute to work on my trusty e bike the poor old car sits on the drive way unloved, sometimes not being used for several weeks. Now, this 2 ton lump of prime Swedish steel has a 110Ah starter battery which loses the ability to start the car after 4 weeks...
  12. RustyKipper

    A bit of lunchtime fun

    It was a cold wet February day, the speedometer on the commuter had stopped working, probably water ingress again. I brought the bike into the factory at lunch time to put some tools to it. Any how with a couple of workmates helping we soon had it working so I climbed aboard and did a circuit of...
  13. RustyKipper

    The simple idea's are always the best!

    I had to replace the aging battery pack on the commuter, it was only an Ebay cheapy and had done a good 9000 miles and anyhow I wanted to get the full potential from the CST rear hub, up to now I had been using a 250W controller (worked flawlessly and cruised at 22 MPH). So, I had a bunch of...
  14. RustyKipper

    36V headlights

    Hey all. Thought I’d just share my headlight build for my extreme commuter. This was brought about by 2 reasons; 1. I hit a nasty pothole on an unlit road way out in the sticks that put me in hospital 2. I keep putingt the light batteries on charge for an hour when I get into work and then...
  15. RustyKipper

    Cool new accessary

    Hey guys, just had to show you my latest e-bike accessary, I couldn't find one in any bike shop..... a 2 foot bow saw! My forest route was blocked by a fallen tree not for the first time. The saw worked a treat. It was a bit dicey riding past the 2 police stations with the saw attached to...
  16. RustyKipper

    Bafang CST and S12S controller without LCD

    Hey Guys, I’m currently nearing fitting my new Bafang CST and S12S controller, just finishing the carbon composite battery box and saving up for the remainder of the 15Ah Headways. So sorry if this question has been asked before but here goes. I know the controller will function without the...
  17. RustyKipper

    spokes and rims

    Morning chaps. Just received my new bafang cst and spokes after three weeks of chasing, unfortunately the motor arived damaged which I believe is not uncommon and the spokes I ordered seem to be of a very poor quality, there is a mix of 2.25 and 2.5mm diameter, the screw ferules seem a very...
  18. RustyKipper

    Solar charging lifepo4

    Morning chaps, I'm looking for a more efficient way of charging my 9Ah E-bike battery from my solar shed. Currently I have a 180W panel charging a 110A lead acid battery in the day that in turn powers a Victron 1200W sine wave inverter powering the battery charger at 230V. This system works...
  19. RustyKipper

    Need more hill climbing power

    Morning folks, I wonder if you chaps could offer any advice about where I might source a rear 500W hub motor that would accept a 9 speed cassette. I have emailed GreenBikeKit but they don’t offer such a beast. A little background info, I have a Garry Fisher Tassajara mountain bike (fab bike)...
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