Specialized Enduro Comp E-Bike with 9C hub

[emergence]

Hi All,

Just about finished setting up my first Ebike Project. This is setup for a 23km commute to work. Top speed 50km/hr. Hauls up big hills nicely at 35kph.

Parts sourced and Torque Arms were designed and made up by EVLAB.co.nz. Really helps to have someone who knows what they are doing help you into this.

Ebike Parts Used:

2x 36v 10ah ping battery with 2x chargers
Rear 9 continents 2808 wind Motor
Infineon 12 Fet Programmable Speed Controller
Spoke Set
Rear Rim ALEX DM24 26" - 36 Hole
9 speed cluster cassette
Custom designed Torque Arms with shims and spacers from EVLAB
Programming Cable For Speed Controller
Battery Bag
Seat post Mounted Carrier Rack
Twist Throttle
Regen Button
Three Speed switch
Battery Extension Leads

Other Parts Used:
Magicshine LED bike light 1600 lumen
front tube mount mud guard(union)
hookworm tyres dual ply
Maxxis freeride tubes
Pipe clamps x2
Exhaust pipe Clamps 40mm & 50mm
Alloy Tube
Butinol rubber
Loctite


To do:
Voltage adaptor for lights and accessories
Key Switch
Motor Cable extension
Proper Controller mount

Hope this is useful for anyone out there looking to setup an enduro!

 

[oatnet]

Nice Job! It's good to see another Enduro Comp build here. What year is that? I think it is newer than mine:

http://www.endless-sphere.com/forums/viewtopic.php?f=6&t=24329&hilit=+enduro

-JD

 

[emergence]

Thanks! its a 2007. Its a Really great bike. Enduro Comps are a pit pricy as donor's but they are so solid which is great at 50kph.

I looked at yours when specing mine out but lipo is no good for my commute as I cannot charge it at work. looks pretty sweet and very stealth. Kiwi from evlab has been playing with fork mounts for batteries too.

 

[emergence]

Just spotted that the main bike pic is a bit small so i'll try again with a bigger one soon.

 

[Danos]

Nice build!! How does it handle? I have the same rack from Kiwi but with less weight in it on a Trek hardtail and i find it fine.

 

[emergence]

Get a bit of torque steer with the power down on a fast corner and all that weight on the back. Nicer in the bag for the twisty stuff and bumps. Still need to replace the metal pins in the rack with stainless bolts. The pins are a pain to get out.

Took this into the belmont regional park again last night
(battery in bag). awesome on the shale and hardpack even with the hookworkms. bogs down on anything technical or steep uphill. I see another offroad specialist bike in my future

 

[Danos]

Yeah i need to replace those pins too, Kiwi emailed some time ago and i haven't done it yet. I'm pretty careful to not hit big bumps when traveling fast but wouldn't want to see my battery come off for the sake of two bolts!!

 

[emergence]

Actually, I just took it out for another run with the battery on the rack (the first long ride with it since I switched from hi-rollers to the hookworms) and the torque steer and cornering stability issues are mostly gone on the road with the much more solid tyres. Seems that was a tyre issue and I need to find a nice solid offroad tyre that is ok on the road (High Roller tyres are way too knobbly on the center strip and it seems don't have enough sidewall support).

Did a bunch of gravel road running and the extra rack support was good. Still a bit of lateral flex but held up well. The hookworms not so much, 50kph on gravel is a bit much for them and I found myself nearly offing on a couple of tight bends. But on the tar-seal its the opposite issue you have to be careful not to overdo it because they hold so well. Easy to find yourself hooning way faster through twisty sections than you would in a car. Particularly uphill where it seems sacrilegious to hit the brakes on a bike.

For offroad I'm finding the 2808 a little dangerous, it really wants to be in the 20-40kph range and it makes you want to go go go rather than cruise and enjoy. A new rig with A geared hub or slower wind would definitely be on the cards If I want to keep going offroad.

Felt a bit guilty when I passed a guy who had clearly just pedalled from the bottom of a big hill, still I can now blat into the hills behind our house, get well out of sight of civilisation and back in a half hour. Pretty cool.

Today I got chased by a dog (no problem with a motor on board ) and rode past a nude sunbather just off the track. It was only 3 weeks ago I downhilled past a couple going at it on the track side fully starkers. Belmont Regional Park: Nature... and Naturalists...

 

[Kingfish]

I have a soft spot for Specialized; my previous ebike was a 1991 Rockhopper conversion. Your build looks great! One suggestion: Move your batteries to the triangle and you will have a better experience all around with the weight lower and centered; a difference you will appreciate instantly! :wink:

Starkers: LMAO :lol:

Happy Trails, KF

 

[Danos]

Today I got chased by a dog (no problem with a motor on board ) and rode past a nude sunbather just off the track. It was only 3 weeks ago I downhilled past a couple going at it on the track side fully starkers. Belmont Regional Park: Nature... and Naturalists...

Classic!! I know Wellington is pretty liberal and a cosmopolitan type of city...and this just proves it!!

I very nearly bought a 2808 kit from Kiwi but opted for the Mac 500w from cell man in the end. I'm very happy with it...fast, light-ish and reasonably stealthy. I wanted to fit hookworms too but they were quite expensive so i went for Schwabe Marathons, no issues with them so far.

 

[etard]

That's a great setup you have there man, props on the rack as well! The best thing about Specialized is they seem to hold thier value well. I bought mine 4 years ago used and I feel as though I could sell it for nearly the same price.

 

[emergence]

Did a test run of some of my commute today and holy moly I could hit 65kph on the (flat) highway cycle lane. Not sure but it must have been the reprogramming of the controller to do 3 speed but it has really opened it up. Can be pretty freaky in traffic tho, need to take it easy... Need to get a big front ring and sadly take off the chain guard if I want to pedal at that speed...

Also I'm having issues with my rear juicy 5 brake rubbing. If tried disassembling, cleaning and centering it but to no avail. guess I might need to get it bled. I've not been able to try the regen yet as the highest setting is for 75v and my batteries have yet to drop below that even after 5ah used.

 

[Alan B]

Nice build, and welcome to ES.

Looks like the motor wiring may not have a drip loop and could help guide water into the motor if you ride or park in wet weather at all.

 

[oatnet]

Also I'm having issues with my rear juicy 5 brake rubbing. If tried disassembling, cleaning and centering it but to no avail. guess I might need to get it bled.

On rear hub motors it is tough (in many cases impossible) to get the hubmotor's sidecovers aligned to the tolerances required for self-adjusting hydraulic brakes. Mechanical disk brakes can be adjusted looser to clear a wobbly disk, sometimes you have to fall back to a rear rim brake.

-JD

 

[emergence]

Thanks Alan, that's a good point that I'd forgotten. The wiring is still temp until I get a motor extension cable and mount the speedo properly, Then i'll turn the motor peg so the slot for the cable faces down and the wire forms the drip loop naturally as well as using some old bicycle tubes to cover all the exposed connectors.

Did my first commute today 24kms in 43mins with a strongish headwind. Top speed on the flat 55kph and controller shut down the batt at about 700mtrs to go. Finally worked out that the regen is set to use the throttle so that will help a bit and need to just back off that top speed slightly to get there in one go with some headroom.

Voltage really holds up above 74v until I've used the full 10ah.

Definitely want an AGV Blade scooter helmet to cover my ears and face. The wind gives me earache and I find I actually can hear better with my old full face helmet on in the wind.

Here is the 2 chargers and battery pack as well as my magicshine battery charging at work:

And Here is a better size pic of the whole bike:

 

[emergence]

After a full days commuting I used a full 10ah getting to work (24.5kms )into a fairly stiff headwind but only 7 on the way home. average speed of 35kph, top speed 60kph (64kph with strong assistance). Times were 43 and 40mins. Just under my target of 45

After checking out the bike the guys at my work were pretty surprised you could go so far so fast with so little.

Need to work out my route through town. Its a bit hairy at times being in a kind of nether world between cyclist and vehicle.

 

[oatnet]

After a full days commuting I used a full 10ah getting to work (24.5kms )into a fairly stiff headwind but only 7 on the way home.

We tend to measure current in Watt Hours instead of Amp Hours, because WH takes Volts into consideration. The formula is WH = AH * V (Watt-hours = Amp Hours * Voltage).

A 72v10ah pack would have twice the WH of a 36v10ah pack, even though they both have the same AH. You probably noticed that the resting voltage decreases as you drain the pack down, so (1) AH on a fully charged pack will have more WH than (1) AH in an almost empty pack. In addition, your voltage drops when you hit the throttle hard (puekert effect), so an AH on light throttle would have more WH than an AH on a heavy throttle.

-JD

 

[emergence]

We tend to measure current in Watt Hours instead of Amp Hours, because WH takes Volts into consideration. The formula is WH = AH * V (Watt-hours = Amp Hours * Voltage).

Yeah, I'm just giving quick readouts off the cycle analyst. I'm calculating wattHours now that i'm investigating the possiblility of a lipo pack for offroading. Here is my idea for a nice tidy Lipo pack:

8 sticks of 6s1p4000mAh Zippy Lipo, Almost same total wattHours of power as my current pack but with much more torque for steep offroad and a bit more speed on my current motor(88.8v). Fiberglass case moulded from polystyrene.

Still a bit confused about how to charge this many packs without a dangerous and crazy complicated setup though...

 

[dnmun]

i think the 9C has sealant goop on the inside of the hub where the wire bundle comes out of the dogleg hole in the axle.

so the loop may be less critical. and there are seals on the axle outside the bearing to keep water out too.

 

[emergence]

i think the 9C has sealant goop on the inside of the hub where the wire bundle comes out of the dogleg hole in the axle.

so the loop may be less critical. and there are seals on the axle outside the bearing to keep water out too.

Good to know but having seen Justin's vid on motor sealing it seems the pressure of the heat differential is the main culprit of water contamination. If you watch it you will see that the pressure of the motor cooling can suck a decent amount of water even through the cores of the power wires!

http://endless-sphere.com/forums/viewtopic.php?f=30&t=34972

to the point that they are now offering pre drilled c9 motors as the best solution to avoiding water sitting in the hub.

 

[dogman dan]

The whole charging thing, along with my need to use lipo on multiple bikes and yard tools, led me to carry my lipo untidy. I'm a fraidy cat, and it make me feel safe to remove the batts each ride, feel if one is hotter, then charge in my version of a safe place.

Just saddlebag type boxes high and away from the knees as possible.


Methods sells complete lipo battery management equipment for safe bulk charging. Hvc,lvc boards. Then you can get bulk chargers from bms battery that are set to your choice of top voltage. So you can bulk charge to 4.1v per cell or whatever you choose. A bit pricey, which is another reason a cheapskate like me still removes the packs to use RC chargers. But it's the current state of the art if you want to just plug in the bike with one plug to charge.

 

[emergence]

Methods sells complete lipo battery management equipment for safe bulk charging. Hvc,lvc boards. Then you can get bulk chargers from bms battery that are set to your choice of top voltage. So you can bulk charge to 4.1v per cell or whatever you choose. A bit pricey, which is another reason a cheapskate like me still removes the packs to use RC chargers. But it's the current state of the art if you want to just plug in the bike with one plug to charge.

Thanks, I need to look into the methods gear. sounds like a good solution for those wanting plug and play. Can you use the lipo chargers to charge my ping LifePo4 36v 10ah packs too? I need a faster charging solution there as well.

And I was reading your other threads about off roading, very helpful and interesting. Thanks.

 

[emergence]

Finally got the R12 resistor mod into the infineon 12fet controller for running regen at over 75v but now my flashing software/cable setup seams to be dead and I cannot tweak the settings.

Regen switches on when you let go of the throttle at full speed. Not nice. Anyone got any tips on getting the controller flashing setup working again?

I've also tidyied up the wiring an added rubber inner tube protection onto all the connectors. Much tidier and not so obviously EV.

 

[emergence]

Got the infineon 12fet programming sorted. the usb cable needed a jumper and now it is flashing the infineon just fine. seem to have the regen switching on with the throttole release but i have a feeling that I may havbe inadvertently switched this on"

Slip Charge Mode (optional)
This is to enable the regenerative braking at speed 15 KPH/10MPH or above (0 = ON, 1 = OFF)

because it is letting go about then.

 

[Kiwi]

Yep, set that off.
With your controller you can set your speed to 120% also, controller should handle that ok.
Basically allowing for a higher switching frequency.
You will probably want your regen level set to 1.
I found some 5.5ah 6s Lipo, 30C for $115US free shipping, I dont know the brand though.
http://www.suntekstore.com/goods-10...+Battery+for+RC+Helicopters+T-REX+600700.html
I buy a bit of stuff of these guys, all gets here, not great quality.