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home brew e-bike
#1
One of my projects is making a e-bike with my26650 A123 cells.

I bought the parts from the UK 1000W 48V motor+controller.
I will have dual speed control -PAS and tumbtrottle.

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

 

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.
beefy SS chain.
38T front ring
11T rear

I will need to upgrade since the 1000W engine will give loads of POWER  Big Grin





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



 

The display a KT-LCD1


 

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






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


  

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!! Tongue

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 mid frame
- 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
rebelrider.mike, BlueSwordM, zag2me And 1 others like this post
Greetz Dennis

www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
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#2
So I started my Battery box.


3 aluminium profile's


sized to fit the frame


curing the epoxy


Glasfiber reinforced polyester plates

and glasfiber tape + epoxy resin to seal it all up

 
battery trial fit with controller 

 
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
hbpowerwall likes this post
Greetz Dennis

www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
Reply
#3
Following. I also want an e-bike some day Smile
The Ultimate DIY Solar and build place
YouTube / Forum system setup / My webpage  Diy Tech & Repairs

Current: 10kW Mpp Hybrid | 4kW PIP4048 | 2x PCM60x | 83kWh LiFePo4 | 10kWh 14s 18650 |  66*260W Poly
Upcoming: 14S 18650~30kWh | Automatic trip breakers, and alot more
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#4
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.

 

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..
hbpowerwall likes this post
Greetz Dennis

www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
Reply
#5
I think you got the P and S mixed up. 17S2P So 54.6V. What is the capacity of those A132 26650 Cells?
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#6
(10-03-2017, 01:39 PM)jdeadman Wrote: I think you got the P and S mixed up.    17S2P  So 54.6V.   What is the capacity of those A132 26650 Cells?

Big Grin atlas some one is paying attention . 2P17S Tongue
Greetz Dennis

www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
Reply
#7
I build one pack for 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-LiFePo4-...2749.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 with discarding at 42.5 Volt.
charged it up to 61,5 Volt and it holds the charge Big Grin .



Let's hope it keeps performing well.
Greetz Dennis

www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
Reply
#8
I finalised my Bike.

 
I used a old 3 pin charge port
 
2P17S pack 54,4V Lifepo4
2 different packs 1 for backup
 
61V charger
 
The final pack with charge cables (small wires)
Discharge cable 2.5mm2 wire

 
48V motor controller
  
detail tuning by mij GF
 
final cover of the box made

  

 
  
 
 
 
 
 

  
Korishan and jdeadman like this post
Greetz Dennis

www.verticallife.nl

Current Of-grit setup
5 230Wp canadian Solar panels
2 Voltmaster 270Ah 12V Battery's
1 Outback flexmax80
1 Phoenix 3000 inverter
Reply
#9
Great job!  I am very interested in the topic of developing engines for unicycle electro scooters and customizing bicycles.  A recent my friend Timur Artemev patented a self-balancing powered unicycle device.  I think it will be interesting to see this!
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