Electric bicycle build (introducing "black & red")

[California98Civic]

The new look of "black and red" ...

I still have some wire tucking to do (thinking this stuff) and a couple other small things, but here it is:



The rebuild took 6 pounds off, gave me a lower center of gravity, and greatly improved handling by bringing weight forward of the rear axle. I also solved an intermittent brown-out problem (turned out to be a loose wire in a connector). I made the bracket for the battery out of the battery box portion that I cut in order to fit the frame triangle. First time I ever have made any sort of mount or bracket. It is very solid. It's not very pretty.

Fully loaded with bike lock, toolkits, parts, battery mount--as in the old photo below--the bike was 51 lbs. Now it weighs 45 lbs.



I hope that moving the weight off the back tire will also reduce the frequency of punctures.

The new bike lock is that rectangle above the top tube. It is a titanium TiGr Mini+, and it coast $135. I love it. It weighs 1 lb. My old lock weighted in at about 2.5 pounds.

[Grant-53]

As much as I like pretty it's safety first. I mounted my handlebar bag on top of the bar and parallel to the ground. The light can mount underneath since I made my own aero bars.

[California98Civic]

Originally Posted by Grant-53

As much as I like pretty it's safety first. I mounted my handlebar bag on top of the bar and parallel to the ground. The light can mount underneath since I made my own aero bars.

Have you posted pics of your setup? I'd love to see.

[Grant-53]

I have three things going at once this week but I will make a concerted effort to do pictures soon. High school graduation, garden planting, and grandkids coming. The bag is by Sunlight and snaps to a plastic frame.

[California98Civic]

So, I figure with the new costs for the remod of this ebike, my total cost is about $1675 now. At $0.55/mile cost for driving (my employer's rate) it would be 3045 miles before I "break even" on costs by riding instead of driving. At the $0.06 rate suggested by my average fuel costs for my EM car, it would be approx 28,000 miles.

Lotta two-wheelin' !!

[M_a_t_t]

What voltage and Ah is your battery pack?

Thanks, Matt

[California98Civic]

Originally Posted by M_a_t_t

What voltage and Ah is your battery pack?

Thanks, Matt

Somehow I missed this question man. Am very sorry. My battery pack is a 14 amp hour Lithium set up for 36 volt system.

[California98Civic]

My ebike battery charger is dead (I tested with a multimeter). Any advice on replacing it? My set up is 36v. I have a 14 ahr lithium battery. The old charger is rated on the case as 43.2 volts and 2.5 amps. It took hours to charge from half depleted. I'd spend a little for faster charging, like maybe a 7 amp charger. Thanks as always for all your useful advice, people.

[Stubby79]

I'm cheap...I'd go source one out on ebay. Just make sure it's designed/rated for the right number of cells and chemistry(though your BMS will probably prevent over-charging...you still need enough voltage). You can always change the plug on it to match your battery's charge port.

There's probably a 5a one out there. I bought a 5a 72v one a while back.

Quick search example:
https://www.ebay.com/itm/371918053640

[California98Civic]

Originally Posted by Stubby79

I'm cheap...I'd go source one out on ebay. Just make sure it's designed/rated for the right number of cells and chemistry(though your BMS will probably prevent over-charging...you still need enough voltage). You can always change the plug on it to match your battery's charge port.

There's probably a 5a one out there. I bought a 5a 72v one a while back.

Quick search example:
https://www.ebay.com/itm/371918053640

Wow, that is cheap! And it is virtually my exact charger, but higher amperage. And mine has the plug with a male stem inside a round barrel. It only has +/- and no ground (I think), unlike this three prong which is grounded. What would I do with the ground wire? Maybe an adapter? Cut it and wrap it? I suppose I could dismantle the battery box and replace the female plug instead. Hmmmm.... I wish there was still a plug and play but I have been looking and suddenly they all seem to be three prong.