home brew e-bike

Joined
Jul 8, 2017
Messages
51
One of my projects is making a e-bike with my26650 A123 cells.

I bought the parts from the UK1000W 48V motor+controller.
I will have dual speed control -PAS and tumbtrottle.

I started with single speed On-One that I build in 2010


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specs:
One-one steel frame+fork
Race-face cranck set
Xt bottom bracket
Avid mechanical disk brake cable routing through the fork 180mm disk
mini steel steer and random alloy Stem
DT-swiss DH hubs spokes and rims small road tires.
beefySS chain.
38T front ring
11T rear

I will need to upgrade sincethe 1000W engine will give loads of POWER :D




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motor wiring and display installed.
48T front ring
16T rear




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The display aKT-LCD1



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The PAS system is installed between the bottom bracket and frame.
The magnet disk is mounted on the square axle.





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The motor controller is a 48VMxus sold by Cyclotricity UK
The Motor is markedCyclotricity marked as 250W restricted. (actual 350W/3000W MXUS)



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54.4 V battery pack "installed"

Test set up is ducked-taped to go, peddle assist set to "5" GOO!

And it's F*cking scary fast!! :p

It's restricted to 250W but still goes 49km/p when peddling hard.
It's possible to fully unlock the 1000W :angel:.

Next:
- making a battery box with charge plug midframe
- integrate the BMS in the box.
- upgrade the disk brakes to hydraulic Front and Back (instead of the mechanical frontbrake)
- front suspension might be nice :shy:
 
So I started my Battery box.


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3 aluminium profile's


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sized to fit the frame


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curing the epoxy


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Glasfiber reinforced polyester plates

and glasfiber tape + epoxy resin to seal it all up


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battery trial fit with controller


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status so far:
its working just need to fix the components inside the box against movement.
and I need to smoothen the box
and make a lid/cover

p.s. Yes thats my dogs "Castle" in the background
 
Following. I also want an e-bike some day :)
 
My e-bike i up and running
I only need to make a lid for the battery box and a BMS/charger for the battery.


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I like to make a bigger battery pack now it 17P2S 54,6V
Or I place 2 battery packs with a switch so I can can use only one at the time.

Other feature will be a integrated LED front light from eBay.
And I like to have a USB charger for my phone not sure how to connect it to the 54V battery..
 
I think you got the P and S mixed up. 17S2P So 54.6V. What is the capacity of those A132 26650 Cells?
 
jdeadman said:
I think you got the P and S mixed up. 17S2P So 54.6V. What is the capacity of those A132 26650 Cells?

:Datlas some one is paying attention . 2P17S :p
 
I build onepackfor my bike.
48V 16S-2P with the same LIFEPO4 A123 3.3 V cells as I'm using in my power wall.

I bought a cheap chinees LIFEPO4 BMS:
https://www.ebay.nl/itm/48V-45A-LiF...e=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649

It's a bit strange it only has a B- (battery minus and) C- (charging minus).
But it works.
I discharged the packing it stopped exactly withdiscarding at 42.5 Volt.
charged it up to 61,5 Volt and it holds the charge :D .


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Let's hope it keeps performing well.
 
I finalised my Bike.


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I used a old 3 pin charge port

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2P17S pack 54,4V Lifepo4
2 different packs 1 for backup

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61V charger

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The final pack with charge cables(small wires)
Discharge cable 2.5mm2 wire


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48V motor controller

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detail tuning by mij GF

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final cover of the box made

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