Project Avalon: E-bike build

[razor02097]

Time for an update...

I went ahead and ordered a torque arm kit. I decided to mount it a little differently though...





Here are the other parts that came with the universal kit.

[razor02097]

Last night I made a spark arrest adapter.



Here is the circuit.

1. How it works is
2. remove the key
3. connect the battery
4. flip the switch to charge up the controller
5. Insert the key to provide full power

Total cost was about $10

[razor02097]

I am also adding a Watts up meter to the dash. I am going to use a 3 wire set up since I am hooking it up as a remote meter. I have it zip tied in to place temporarily to see how it will look. I will use some double stick to mount it on the bracket.



Here is the bracket. It's actually a reflector bracket I took off when I put on the rear safety light.


More to come once it's hooked up.

[razor02097]

The watts up is mounted and wired in.




Also picked up a mirror

[razor02097]

Since I'm still waiting on the seller to either make right or send a shipping label for the used battery that was sold to me as new I am making a NiMH battery to get Avalon going.

The batteries are D cell NiMH 10aH batteries.


There are 2 bricks of 20 batteries all wired in series to make a 48V battery pack.









The dividers are made from heavy plastic. The outside is just going to be tape. The battery is 48V 10aH and weighs 13.6 lbs.

[razor02097]

First voyage out the battery lasted 11.1 miles with pedaling. The kill-a-watt says the charger and battery took .35KWH according to my math that is 31.5 watts per mile. I have no idea if that is good. I didn't have the watts up meter for the maiden voyage so next time should be interesting.

I figure if I had to buy an equivalent amount of fuel to go 11.1 miles with a gallon of gasoline at $3.699 and a KWH at $0.062...(Duke charges 6.2 cents per KWH over 1000 KWH...)
(.35KWH X $0.062KWH) = $0.0217 is the amount to charge battery...
($0.0217 kwh / $3.699 gal) = 0.006 gal amount of fuel I could buy with $0.0455
(11.1 miles / 0.006 gal) = 1850 MPGe

I know NiMH batteries need a period of time and cycles to run in... so range should improve. I think my 50 mile range is a pipe dream with what I have. I would have to pedal more than half of the distance with a 20Ah battery.

That said it is sufficient for running a few errands... I rode around for a little over an hour... plus I did use assist almost the whole time. The top speed on flat ground is 26 MPH throttle pegged.

[meelis11]

Is that Nimh pack temporary while waiting some other pack or you will stay with it?
How much it cost to make NIMH pack?

For me best thing seems to buy RC LIPO batteries from hobbyking - you can get 22V 5000mAh LIPOs around 50$ - to make 10Ah battery it costs around 200$ (need 4 of them)

[razor02097]

Cost was about $300 which includes the charger and connectors. I am still fighting with the scammer that sold me a used battery as new so it is semi permanent.

[meelis11]

Quite expensive semi-permanent solution you have.

[razor02097]

There is no cheap solution if you go with a 48V system.