Aprilia custom Crystalyte Powered

[Deeze]

Hi community this is my first post on here and am passionate about the whole electric bike builds and am an electrical engineer and have a high mechanical aptitude so hopefully I can be an asset. I am currently in possession of an Aprilia Enjoy Racing - I had been searching around for quite a while looking for something stealth but had the build quality and engineering to handle 5-10kw and still not look too red hot for the boys in blue. This is my thoughts on the project thus far; I have read good things about Crystalyte and chosen to go with them unless I'm reasomly advised a viable alternative. I was thinking of front and rear both Crystalyte however I would like a 80 crown on the rear and in the future a front hub but ATM just rear wheel drive. I have a dead weight original controller but great g/box and motor on it now. I'm building a custom 16s2p 20AH 48v system using 10ah cells. I would like to know where I could find the best deal in Australia for a Crown 80 and a 48v 50A controller ( Crystalyne ) I have found deals on eBay from hi powered but also read in a forum post about an Aussie on here who had some great custom Crystalyte gear if anyone may know his alis that would be great. So considering the build dream what are the community's input - I have been reading about oil cooling some of the earlier hubs 3 series but I Dont think a crown would need it due to its wider stator as I'm concerned about saturation and demagnification of the magnets so i think a decent pc programmable controller is a definate. I am also interested in a decent BMS Any inpup will be warmly received - Thanks in advance Deeze.

 

[Deeze]

I wanted to upload some pics on here so people could follow the build. Any input is welcome but do realise the way I build is I rough everything in first then test, modify, tidy and commission in that order.

 

[Deeze]

The frame is a magnesium alloy construction. Unsure of whether it will be strong enough but it looks the part. I will be adding stainless bar to make a rear triangle for support and the torque arms.

 

[Deeze]

Uninspiring, inaccurate looks cute but is just plain nasty.

 

[Deeze]

200W brushed DC motor....works well on the stock wife's bike but on this build it has got to go.

 

[Deeze]

Stock bars

 

[Deeze]

Stripped naked and got LiFePo4 ghetto pack strapped on.

 

[Deeze]

Thanks to Hyena Bikes for the help with the motor.

 

[Deeze]

Needs love.

 

[Deeze]

Boxxers, EX823's plus some Stans gear and Hookworm 2.5 are a good start.

 

[Deeze]

The forks steering tube was too short and a new one costs more than I paid for the forks. After several hours on the lathe and press we have a stainless steel made and fitted. The thought of me doing 80kph and not eating concrete was a great inspirator during making of the tube.

 

[Deeze]

 

[Deeze]

This is early in the build when I was sizing up a custom stainless steel battery box for the frame and taped on Kelly Controller so I could have a look at the controllers software on the laptop. Software package looks nice.

 

[Deeze]

New DH bars fitted chosen for their relative low profile whilst still providing a cross bar for the Cycle Analyst V3 on.

 

[Deeze]

Hope Pro 2 Evo red 20MM Hub laced to a Mavic EX823 with black spokes.Sexy as hell.

 

[Deeze]

Stainless steel battery tray made and doubles as a frame support.

 

[Deeze]

Battery box temporary mounted. It's a custom battery made from S/S lined with rubber and nylon sheeting on the base to prevent short circuits when the battery takes some knocks. The battery I've chosen to build is made from 24 Headway cells giving me a nom. Voltage of 72V @ 10AH.

 

[dogman dan]

Coming along nicely. I'd call it a good frame choice.

 

[Hillhater]

Poor frame choice for high power with big battery pack.
I have one with up rated pack and controller ~~1.5kW, and at 50kmhr the frame gets pretty squirley !
What are you going to use for a bottom bracket ?

 

[Deeze]

Getting the rear wheel laced was a huge drama on this build. I'm sure I've had a personal influence on googles servers whilst researching lacing an EX823 into a Crown Motor. This is ongoing but for the sake of personal experience/inteague i have gone ahead and laced it myself as I contacted wheel builders who were recommended on here and their resonse was that they wouldn't help me and I should try it myself....which I have just to get the old girl off the ground and rolling again.

 

[Deeze]

Poor frame choice for high power with big battery pack.
I have one with up rated pack and controller ~~1.5kW, and at 50kmhr the frame gets pretty squirley !
What are you going to use for a bottom bracket ?

I could have gone "balls out" and built something which would look like a motorcross 750cc dirt bike going down the sidewalk but I'm thinking that would draw a lot of unwanted attention - I'm hoping when I'm finished with this build and it has all its plastic thrown back on it it will look somewhat original only with a crown hanging out the arse end....maybe I will have tassles coming out the handlebars for diversion tactics . Truthfully thou I can see how this frame may suffer from lateral load impacts and torque/loading of the frame due to the absence of decent triangles but I'm hoping that the battery tray ( which by the way could itself be stronger than the most hard core frames out there as it has dual 5mm x10mm strips that are welded in ) and battery box itself.The rear end issue I for see of it getting out of shape at speed will be negated by the dual 5mm solid stainless bars that I'm still to fabricate. As for bottom bracket - the original gearbox would be great as it has torque and pedlic sensors built in.

 

[Deeze]

Thoughts of rear end strengthening and torque arms leaves me to think of killing two birds with the one stone in the form of 5mm solid bars from the bottom bracket to the torque arms.

 

[Deeze]

Up and running...just

 

[Deeze]

Up and running...just

 

[Deeze]

Up and running...just