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Project Electric (Push) Bike - Now With Video

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Aff
World Chat Champion



Joined: 05 May 2011
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PostPosted: 09:05 - 11 May 2014    Post subject: Reply with quote
Charlie wrote:
I was pleased to hear that you where going to fit a cut out board, but I am yet to see it! Also you're very brave tagging batteries on your own!! Did you have a plan in case one went 'hot'?

Cool project though Thumbs Up


One did, it got thrown in a bucket of salt water in the garden for a month or so.

This new controller has its own cut out board, which seems to work fine. I may still but an extra one though.
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Charlie
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Joined: 27 May 2007
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PostPosted: 09:13 - 11 May 2014    Post subject: Reply with quote
Something in the battery pack would be good, if something happens to the wires from the pack to the controller at least you've got some back up.

Still bloody brave tagging at home!
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Aff
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Joined: 05 May 2011
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PostPosted: 10:50 - 24 May 2014    Post subject: Reply with quote
Taken the bike on a few more runs, it's great fun.

Took it up this hill the other weekend:

https://i1135.photobucket.com/albums/m637/Biles/EBike/HILL_zps8de38cbe.png

Managed to average 26 mph, nothing got hot, nothing complained. Motor was drawing about 25-30A the whole way.

I have ordered a custom made chainring too. With the current 44T I spin out at about 20 mph, which isn't very good. Me helping the motor reduced the consumption massively. I have a company in Mericaland making me a 52T ring that will fit on the MTB cranks. Should mean I can pedal up to 25 mph which will be a nice cruising speed.

I have also bough a load of high flex silicone wire to remake my packs with. The current stuff is getting a bit stressed with all the plugging and unplugging.

I also have a sample of 18650 cells coming from China, they work out at less than 60p a cell brand new with a supposed 3000mAh capacity. I will test them when they arrive but I am expecting them to be fakes. If they aren't it will be nice and will probably make myself a 72V pack for moar powars.
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Aff
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PostPosted: 14:23 - 24 May 2014    Post subject: Reply with quote
New balance wires put in using high flex silicone wire.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_20140524_140631_zps7kalbokz.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_20140524_140736_zpsxmrbssev.jpg
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G
The Voice of Reason



Joined: 02 Feb 2002
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PostPosted: 14:41 - 24 May 2014    Post subject: Reply with quote
Wouldn't it be better to put some road cranks on?

On my hybrid I've got 50/34 on the front and 11-34 on the back.
I've had 44mph on the GPS, on the tri-bars with me spinning pretty fast and adding a teensy bit.

With a half-electric job I'd be tempted to go for a 54/39 on the front and 11-34 on the back.
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Aff
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PostPosted: 15:16 - 24 May 2014    Post subject: Reply with quote
G wrote:
Wouldn't it be better to put some road cranks on?

On my hybrid I've got 50/34 on the front and 11-34 on the back.
I've had 44mph on the GPS, on the tri-bars with me spinning pretty fast and adding a teensy bit.

With a half-electric job I'd be tempted to go for a 54/39 on the front and 11-34 on the back.


I looked into it, but this chainring ended up being cheap.

I can only have a single speed freewheel, so 16T is the smallest I can fit on the back.

Replacing the large ring and moving the current large to the middle is the simplest option I have. Will give me 52-16 and 44-16 which should be OK.
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Pete.
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PostPosted: 15:34 - 24 May 2014    Post subject: Reply with quote
You can't put a cluster just forward of the wheel and link that to the freewheel with a short chain?
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Aff
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PostPosted: 15:37 - 24 May 2014    Post subject: Reply with quote
Pete. wrote:
You can't put a cluster just forward of the wheel and link that to the freewheel with a short chain?


Too much fab work. Would be much easier to buy a frame with wider stays.

Or even better buy a full sus and make a custom swingarm. Then I could do whatever I want.

Would be nice to have a steel frame too.

This will all happen in mark 2 though. When I have some spare money and time I will try making something stupid. Laughing
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Aff
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PostPosted: 16:12 - 24 May 2014    Post subject: Reply with quote
Just won 25 laptop batteries for £1 each. Very Happy

Thats going to be around 8p per cell depending on how many are dead.

1p per Wh. Laughing
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sensi5446
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Joined: 12 Feb 2014
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PostPosted: 17:35 - 24 May 2014    Post subject: Reply with quote
This is something from my childhood dreams, looks like loads of fun, amazing!! I want one Laughing

What is the law side of riding an electric powered bike? Is there a max amount of power you can use on the road? What's the max speed you've got so far and what distance are you getting on one charge?

keep it up Smile

cheers
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Aff
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PostPosted: 18:17 - 24 May 2014    Post subject: Reply with quote
sensi5446 wrote:
What is the law side of riding an electric powered bike? Is there a max amount of power you can use on the road?


Yep, 15mph and 200W.


sensi5446 wrote:

What's the max speed you've got so far and what distance are you getting on one charge?


It hits about mid to low 40s down a slight hill. This isn't limited by the power but how the motor is wound. To get a higher speed you need to give it more voltage.

With some pedal assist and using the throttle sensibly I think I could get it about 60 miles. Managed about 24 the other day and used about 35% capacity (the capacity becomes less useful the more you use).
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Aff
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PostPosted: 14:46 - 26 May 2014    Post subject: Reply with quote
Just won 53 laptop batteries for £51. Stuff will soon be happening. Very Happy
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bikertomm
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PostPosted: 17:03 - 26 May 2014    Post subject: Reply with quote
Man that shit is hilarious.

Epic. Thumbs Up
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HotdogMcDraw
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PostPosted: 19:39 - 26 May 2014    Post subject: Reply with quote
Aff wrote:
Just won 53 laptop batteries for £51. Stuff will soon be happening. Very Happy


How many batteries have you got now? Very Happy

Enjoying this, are you going to post more vids?
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https://www.bikechatforums.com/viewtopic.php?t=284963 - What to expect on a MOD 1 (contains video footage) - Posted by BG5067

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Aff
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PostPosted: 19:45 - 26 May 2014    Post subject: Reply with quote
HotdogMcDraw wrote:

How many batteries have you got now? Very Happy

Enjoying this, are you going to post more vids?


Gonna have nearly 1000 cells now, will let me pick and choose the perfect ones.

I did record the last time I took it out, but it's all much of the same thing.

Is there anything specific you wanted to see?
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G
The Voice of Reason



Joined: 02 Feb 2002
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PostPosted: 20:22 - 26 May 2014    Post subject: Reply with quote
If you end up wit a good number of decent ones, I'd be interesting in a 36v setup, if the price was right Smile.
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Aff
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PostPosted: 20:53 - 26 May 2014    Post subject: Reply with quote
G wrote:
If you end up wit a good number of decent ones, I'd be interesting in a 36v setup, if the price was right Smile.


Do you have a balance charger set up? I not sure I would trust recovered 18650's over a long period if not being balanced.

I've never tested it though, so can't know for sure.
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G
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PostPosted: 21:33 - 26 May 2014    Post subject: Reply with quote
I don't this second, but would if I got such a setup - been meaning to get one anyway to charge and monitor *stuff* generally.

Don't have any lithium 36v charger right now, only a lead acid one at that voltage anyway.
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HotdogMcDraw
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Joined: 06 Nov 2013
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PostPosted: 22:14 - 26 May 2014    Post subject: Reply with quote
Aff wrote:
Is there anything specific you wanted to see?


Nothing specific, i just like the idea of your project and am interested in how it's advancing, don't worry, i'm not spying Smile.
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https://www.bikechatforums.com/viewtopic.php?t=284963 - What to expect on a MOD 1 (contains video footage) - Posted by BG5067

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Aff
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PostPosted: 17:44 - 29 May 2014    Post subject: Reply with quote
Just picked this up:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0592_zps140c430b.jpg

Karma to anyone who can guess what I'm doing. Very Happy
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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 21:46 - 29 May 2014    Post subject: Reply with quote
Pete. wrote:
G wrote:
From what I've seen, when you start to get over 2500-3000w, push bike drive chains and so on are likely to start failing fairly quickly.


Hardly surprising, since that's more than moped power, and between 5 and 10 times normal pedal power depending on who is pedaling.


Speak for yourself! I has myself measured at 1289W peak Laughing
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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 21:52 - 29 May 2014    Post subject: Reply with quote
Aff wrote:
Just picked this up:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0592_zps140c430b.jpg

Karma to anyone who can guess what I'm doing. Very Happy


Flux capacitor?
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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.
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HotdogMcDraw
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PostPosted: 22:07 - 29 May 2014    Post subject: Reply with quote
Just guessing as it has "capacitor" in the photo so something to do with charge storage capacity.
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https://www.bikechatforums.com/viewtopic.php?t=284963 - What to expect on a MOD 1 (contains video footage) - Posted by BG5067

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Aff
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PostPosted: 19:28 - 30 May 2014    Post subject: Reply with quote
These turned up yesterday:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0593_zpsbb92e514.jpg

Seller said that he usually has an 80% working rate, so I was hopeful.

Many cuts and about 4 hours later:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0594_zps7b8b9ea1.jpg

Very happy. The left box is full of very good cells, all reading above 3.5V.

The right box is between 2-3.5V

I had about 10 cells that were under 2.

This is a million times better than the original set of batteries. I shall begin charging them soon.
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Aff
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PostPosted: 20:34 - 30 May 2014    Post subject: Reply with quote
OK, so I definitely wasn't going to solder this lot together to charge them. So needed a new way.

This is what I came up with:

100 10mmx2mm Neodymium Magnets.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0596_zps59f47d37.jpg

30m of Nickel Strip.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0597_zpsa7d72eab.jpg

I put a magnet on each end, then ran the nickel strip over them to parallel them all up.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0598_zpscb5a9dab.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0599_zps290e7109.jpg

So this lets me charge 50 all at the same time.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0600_zpsfdfd8a2e.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0601_zps5c8b76d7.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0602_zpsf8b1dfee.jpg

Will still take ages though because I have about 800Ah of cells to charge...
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