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Project Electric (Push) Bike - Now With Video

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Pete.
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PostPosted: 21:30 - 30 May 2014    Post subject: Reply with quote

How much did the fire-proof carpet cost? Very Happy Very Happy Very Happy
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Aff
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PostPosted: 21:35 - 30 May 2014    Post subject: Reply with quote

Pete. wrote:
How much did the fire-proof carpet cost? Very Happy Very Happy Very Happy


Shhh. Don't jinx it.
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Aff
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PostPosted: 11:17 - 31 May 2014    Post subject: Reply with quote

OK, first batch of 50 charged.

I have changed my setup a bit. I spaced them out so much because it made it much easier to put together, the magnets are so strong that it is constantly tying to turn itself into a big ball of firey mess.

The downside of this is that I cant pass much current through the nickel strip and I dont have enough to layer t up over that distance.

The strip was hitting about 50 deg C at about 15A. So I spent some extra time and done this:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0605_zpsefbf12d1.jpg

This lets me put lots of layers of nickel strip to handle the current.

This has halved the temperature of the nickel strip:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0606_zpseae8ed79.jpg

Now I'm being held back by the croc clips. they get very hot above 15A and this charger is capable of 40A so I will try and do something about it so I can reduce my charge time. These amperage levels are nothing for the cells, they are all rated at about a 1C charge rate, meaning that this lot of cells can be charged at about 130-140A, so charging at 15A or even 40A is absolutely nothing to them.

These also turned up this morning:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0604_zps37be3e0a.jpg

Not so hopeful about these, but they were cheap and I have plenty of good cells now.

:edit: Changed all the croc clips to soldered on 10AWG wire, now changing at 25A, stip is at about 30 deg C.
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Aff
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PostPosted: 19:56 - 02 Jun 2014    Post subject: Reply with quote

These just arrived from Chinaland:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0621_zpsaa5feb28.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0622_zps9e1e1385.jpg

They are a battery spacer, similar to what is used in the Tesla Electric cars (they also use 18650 cells). They have dovetails on all sides so can be configured in anyway you want.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0623_zps9d20eb21.jpg

And then you just cap the ends of the cells with them.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0624_zps66450072.jpg


https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0626_zps0d49c4f0.jpg

They make the pack very strong, whilst also leaving an even air gap between all the cells to help with hotspots within the pack. The one I'm holding is a 4V ~25Ah cell.

I will configure them like this:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0627_zps61a8a91f.jpg

This is the same as my configuration on the V1 pack, 6s12p. So 24V ~25Ah. I will have 3 of these on the bike.
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Aff
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PostPosted: 17:12 - 06 Jun 2014    Post subject: Reply with quote

OK so everything has had its initial charge. I will be discarding any that loose voltage over a week or so.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0628_zpsda9fca31.jpg

The rest I will be splitting into packs of 12. Because I have such a mix of cells I will have to then discharge all these cells individually and check capacity, then I can match all the cells up and try and get a capacity of about 20Ah in each cell.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0629_zps21e35975.jpg

Also to tryand solve my braking problem I bought this:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0633_zpse2877f87.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0634_zpsb9ca1771.jpg

Its a bit of a beast. Laughing
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stevo as b4
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PostPosted: 20:03 - 06 Jun 2014    Post subject: Reply with quote

I like the trick new oversize disc!
Need to get a bigger disc on my Giant, as it's only a 160mm, which is a bit lacking at speed really. Thumbs Up
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Gazz
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PostPosted: 23:42 - 06 Jun 2014    Post subject: Reply with quote

This thread is fucking amazing. You are a genius!!! Thumbs Up

Cant wait for more updates.

What was the box thing for? (I know nothing of batteries or physics).

TT Zero for you next year my friend. Mugen wont stand a chance.
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Aff
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PostPosted: 08:35 - 07 Jun 2014    Post subject: Reply with quote

Gazz wrote:
This thread is fucking amazing. You are a genius!!! Thumbs Up

Cant wait for more updates.

What was the box thing for? (I know nothing of batteries or physics).

TT Zero for you next year my friend. Mugen wont stand a chance.


Cheers. Very Happy

Box thing?
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KLR600
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PostPosted: 19:54 - 07 Jun 2014    Post subject: Reply with quote

The bigger disc will definitely help but it's that Avid brake that is the main problem. I have 3 Avid brakes and they're all a bit rubbish once you really get going. For the kind of speeds you're going you should really be upgrading the brake as a whole. I'd look at something like a Shimano Saint or a Hope Tech 3. Yes they're expensive but I'd much rather have something like that on a bike that you'll be zipping around on at 40mph.
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Aff
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PostPosted: 19:57 - 07 Jun 2014    Post subject: Reply with quote

The actual braking force is fine, can still stoppie at most speeds (which I think is quite good considering all that weight at the back). It just has a ridiculous amount of fade.

I'm gonna give these a clean and a good bleed and see how things go. If not will have to upgrade. Cheers for the suggestions.
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KLR600
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PostPosted: 20:25 - 07 Jun 2014    Post subject: Reply with quote

Aff wrote:
The actual braking force is fine, can still stoppie at most speeds (which I think is quite good considering all that weight at the back). It just has a ridiculous amount of fade.

I'm gonna give these a clean and a good bleed and see how things go. If not will have to upgrade. Cheers for the suggestions.


The fade is not going to improve with those Avid brakes regardless of what pads you put in them or what disc you fit or what brake lines you have. Those Avids come OEM on a lot of low to mid range serious mountain bikes and they have a reputation for not being very good once you're out of the car park at the trail head. I'm pretty sure the only MTB brake brand that has a worse reputation than the low end Avids is Hayes so I'd avoid those too if you go to upgrade.

Like I said, I have 3 of those Avids and they all fade before the end of a DH run lasting a few minutes. I have an old Hope M4 on the front of my DH bike though and it's great. Consistent stopping power all day long with great feel.
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Gazz
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PostPosted: 21:01 - 07 Jun 2014    Post subject: Reply with quote

How much have you spent putting it all together?

Excluding the trial and error parts?
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Aff
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PostPosted: 22:36 - 07 Jun 2014    Post subject: Reply with quote

Gazz wrote:
How much have you spent putting it all together?

Excluding the trial and error parts?


Really not that much.

If you don't include the bike (cost will vary massively) maybe about £250-300. Making my own battery saved a huge amount of money.

KLR, can you recommend any cheaper alternatives to the ones you mentioned? I can't really justify that cost and if the Avids are as bad as you say they are I imagine there will be plenty of better alternatives. Very Happy Thumbs Up
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MattWadz
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PostPosted: 23:00 - 07 Jun 2014    Post subject: Reply with quote

Avid Juicy brake?
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Aff
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PostPosted: 23:05 - 07 Jun 2014    Post subject: Reply with quote

MattWadz wrote:
Avid Juicy brake?


Yea, 3's I think.
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G
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PostPosted: 10:34 - 08 Jun 2014    Post subject: Reply with quote

If you wanted cheap, you could consider some sliding pin pit bike brakes - but chunky and you'd need to make a bracket etc.

But then, keeping adding more weight and you'll need more power. Which will need strong components. And... then you've got a pit bike, basically Smile.
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chris-red
Have you considered a TDM?



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PostPosted: 14:46 - 08 Jun 2014    Post subject: Reply with quote

G wrote:
If you wanted cheap, you could consider some sliding pin pit bike brakes - but chunky and you'd need to make a bracket etc.

But then, keeping adding more weight and you'll need more power. Which will need strong components. And... then you've got a pit bike, basically Smile.


What about those ice tech pads? Fade is because of heat right? Heatsinks on the pads = less heat = less fade
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G
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PostPosted: 15:07 - 08 Jun 2014    Post subject: Reply with quote

Hadn't seen them before, but yes - makes sense.
Could even add fins to calliper, presumably.
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chris-red
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PostPosted: 00:10 - 09 Jun 2014    Post subject: Reply with quote

G wrote:
Hadn't seen them before, but yes - makes sense.
Could even add fins to calliper, presumably.


That wasn't aimed at you specifically, dunno why I quoted you!
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KLR600
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PostPosted: 00:15 - 09 Jun 2014    Post subject: Reply with quote

Aff wrote:
KLR, can you recommend any cheaper alternatives to the ones you mentioned? I can't really justify that cost and if the Avids are as bad as you say they are I imagine there will be plenty of better alternatives. Very Happy Thumbs Up


Honestly that Saint at £127 is going to be a good bet I reckon. I'm purposefully recommending DH/Gravity hydraulic brakes over trail/XC brakes as they strike a good balance between brake power and heat dissipation. To give you an idea, the top of the range Avids come in at around £150 each on Chain Reaction Cycles. You'd only really need a front brake too I reckon as that's where you'll be doing the majority of your braking anyway.

I suppose it's a bit pricey when you consider that you can pick up some used R1 blue spot calipers for less than £70 on ebay. It'd just be a shame to get a thread update where you've crashed into a hedge because you couldn't stop in time!

There are some offers about on second hand stuff too.

Hope M4 front brake 1

Hope M4 front brake 2

Hope M4 front brake 3

That was just a quick search of the first few results on ebay so I'm sure you could find a good deal with a bit of scouring. Make sure the caliper will fit your fork or that you have an adapter to make it fit though.

Saying all that, you might end up being fine with just this disc. I know if it was me and I was making something faster I'd be sure to think about slowing down faster too though Laughing Thumbs Up
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G
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PostPosted: 00:23 - 09 Jun 2014    Post subject: Reply with quote

KLR600 wrote:

I suppose it's a bit pricey when you consider that you can pick up some used R1 blue spot calipers for less than £70 on ebay. It'd just be a shame to get a thread update where you've crashed into a hedge because you couldn't stop in time!

Speaking of which, I once put an entire R6 front end on a push bike, though I only connected up one Brake disc I think - that had 'adequate' stopping power, even for the extra 40kg of weights I added to it, to simulate the sort of weight converting the rear end to R6 along with a few other bits would add. (Total weight around 76kg I think it was.)

Did get up the VERY steep hill behind my place ok, albeit very slowly - but still overtook the cyclist that had earlier overtaken me, but had got off to walk Smile.
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KLR600
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PostPosted: 23:56 - 09 Jun 2014    Post subject: Reply with quote

G wrote:

Speaking of which, I once put an entire R6 front end on a push bike, though I only connected up one Brake disc I think


I remember seeing photos of that thing floating around on here years ago - wasn't it a yellow and black Carrera? Weren't you going to ride the London to Brighton thing on it? Laughing
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G
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PostPosted: 00:14 - 10 Jun 2014    Post subject: Reply with quote

Yea, that was it - never got around to finishing it, as with so many of my rides. Did do 10 miles or so with the weight above on it.
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400bandit
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PostPosted: 20:08 - 10 Jun 2014    Post subject: Reply with quote

https://www.chainreactioncycles.com/shimano-deore-m615-disc-brake/rp-prod108802

Got to be an upgrade on the avids, get good reviews too
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G
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PostPosted: 20:39 - 10 Jun 2014    Post subject: Reply with quote

400bandit wrote:
https://www.chainreactioncycles.com/shimano-deore-m615-disc-brake/rp-prod108802

Got to be an upgrade on the avids, get good reviews too

I got one of those for the front of my hybrid - which is quite heavy with all the extra stuff I've got on it and normally full-ish panniers.

It does the job ok for my uses and is a little better than the cable brake it was replacing (I needed new pads anyway, so thought for an extra £20-25, I might as well get a whole new front brake system.)

But, think I'd be aiming higher for a bike that would likely have more stopping from speed.
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