Budget DIY Build under $500

ahgnus

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Apr 5, 2016
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Maryland
I am trying to DIY BBS02 kit under $500. I am talking about $500 all in; BBS02 kit, battery, charger, etc. Everything I need to hit the road at around $500. 2012 Cannondale SL4 Hardtail* is the only mode of transportation for me, and my knees can't take the daily ride to work much longer. I need an electric conversion, and I got my sights on BBS02 since many people are starting to upgrade to BBSHD.

Everyone tells me that it can't be done. But I am determined to make it happen with a used BBS02 kit (~$250) coupled with SLA battery setup(~$250). I am sure there is a BBS02 kit sitting in someone's garage somewhere not being used, and it's a matter of time before I find one at a decent price. The real hurdle of this ambitious and desperate project is not about hub motor or mid motor, but the battery. Not many ways to cut corners with it. Using Searchtempest, I contacted EVERYONE on Craigslist with e-bike who had 48V/52V batteries and asked if they would part out the batteries only, and I found a handful who were willing. But I just couldn't pull the trigger when I didn't REALLY know what condition these batteries were in. I didn't want to drop my last few precious dollars on a dud block. I see plenty of ebay batteries around $200 from china, but I have no idea who is trustworthy.

So now I am in search of good SLA batteries. I can live with a 25lb DIY battery pack w/charger for $250. Any battery gurus out there who can recommend me right SLA batteries and chargers for this application? Any and all input for $500 budget build will be much appreciated. All donations welcomed.

(*This is my daily commuter with 26" wheels, aluminum frame, aluminum front fork w/suspension lock-out, stock 24 gear, mechanical disc brakes; 15 miles daily on average - no crazy slopes, some stop and go through traffic lights, 3 mile stretch of unobstructed straight way, little bit of off-roading through hard-packed dirt roads when I decide to take short cuts. Water-proofing the build is a concern of mine also since I ride in the rain or snow. I chose BBS02 for its ability to take advantage of existing gears for torque and speed. I will be a happy camper with about 30+mph top speed.)
 
If your budget is $500, I would forget the BBS02 and spend the bulk of the money on a good quality 36v lithium battery. It will last a lot longer than the lead acid, provide better capacity and more enjoyable without the heavy weight. You can get an inexpensive geared or direct drive motor very cheaply, like $125. The hub motor will be more reliable and require less maintenance than the Bafang mid-drive.

36V Lithium battery $200-350 is realistic. 30mph is not realistic due to the battery required for that. Aim more for 20mph.
 
It can be done.
But right now from the start, forget the SLA, total waste of time and money.
Start with this kit;

http://www.ebay.com/itm/48V1000W-26-Rear-Wheel-Electric-Bicycle-LCD-Display-Motor-Kit-E-Bike-Conversion/371289491857?_trksid=p2045573.c100

$250

and two of these batteries;

http://www.hobbyking.com/hobbyking/store/__64437__Multistar_High_Capacity_6S_8000mAh_Multi_Rotor_Lipo_Pack_US_Warehouse_.html

That's 8 Ah of 46 V goodness for $130 shipped.

This power supply for a bulk charger;

http://www.ebay.com/itm/AC-110V-220V-to-DC-48V-7-5A-360W-LED-Strip-Volt-Transformer-Switch-Power-Supply-/291399498983?hash=item43d8c37ce7:g:CZsAAOSwrklU-T7B

It will need a small mod to limit current-$30 and

A couple of these;

http://www.hobbyking.com/hobbyking/store/__18604__HXT4mm_Battery_Harness_14AWG_for_2_Packs_in_Parallel.html

$10

and a couple of these;

http://www.ebay.com/itm/RC-HobbyKing-Battery-Medic-System-2S-6S-/251611654345?hash=item3a953928c9:g:tBoAAOSwo8hTnmGY

$30

$20 for misc connectors

$250
$130
.$30
.$10
.$30
.$30
---------
$480
 
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