Just built my first ebike

Yuriman

Diamond Member
Jun 25, 2004
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Is this the right forum section? I'd keep it in my garage if I had one.

Last week I picked up a bike in need of a bit of TLC off Craigslist. It checked a few important check boxes - 700C wheels, steel frame, and no rear suspension. The chain needed some love, I thought I'd need to replace the brake calipers, and everything needed adjustment, but after a few hours it rode like a brand new bike. Naval jelly and some elbow grease got all of the rust off, and some clear coat will keep it off.

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I also ordered this stuff:

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Accessories I chose: LED display ($40 cheaper than LCD, but no speedometer or trip meters), thumb throttle, rear mounted with 7-speed freehwheel to match the derailleur on the bike.

Geared motors are not completely silent like direct drive motors, because they have moving parts inside them (orbital gears). These gears will eventually wear out too, so they're not entirely maintenance-free, but I'm guessing the lifespan is in years, and replacement is a ~15 minute and $15 ordeal. They're smaller and slightly more efficient than direct drive hub motors, and have a lot more torque at low RPM. They free-wheel, so no regenerative braking, but you can ride with zero drag if the motor is off. I opted for the 500w model as I intend to still ride this bike as a bike, had some concerns about the longevity of gears in the 1200w geared model. Plus, eBay has some killer deals on 36v batteries right now and the 1200w only comes in 48v flavors.

The LG and Samsung cells for sale in 4.4kWh packs right now are a steal. Ordering in larger quantities results in a lower price - 5 batteries would cost $25 each. The spec sheet for the cells shows they're good for ~360w continuous drain per battery pack, so I only needed 2 to support a 500w motor but decided to go with 3 to be a bit more gentle on them, and so I'd have a spare if the cheap eBay BMS gave up the ghost on one of them.

Assembly took about an hour. Pretty stealth!

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The batteries take up about this much space in the bag:

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It accelerates a bit better than a 50cc scooter if you're not pedaling. Top speed is ~20mph, give or take, which is fast enough for me on a bike. I don't know the range yet but I did about 10 miles of riding today, pedaling but not strenuously, and the battery gauge is still showing full. Some calculators I've played with suggest I can get about 30 miles out of it if I don't pedal, and 60-80 miles if I do.

Total, buying the bicycle, a rack for the rear, ebike parts and a bunch of goodies, I'm in less than $400. I'm hoping to cut down on my city driving, and I expect it will pay for itself in maintenance and gas in no less than a year or two.
 
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Demo24

Diamond Member
Aug 5, 2004
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Neat! So can it spin the wheel without spinning the pedals?


Also, unless you are on the short end that saddle is probably way to low.
 

Yuriman

Diamond Member
Jun 25, 2004
5,530
141
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Neat! So can it spin the wheel without spinning the pedals?


Also, unless you are on the short end that saddle is probably way to low.

Yep, the pedals don't turn if you press the throttle.

And, as the seat is adjusted right now, I'm up on my toes very slightly.
 
May 13, 2009
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Yep, the pedals don't turn if you press the throttle.

And, as the seat is adjusted right now, I'm up on my toes very slightly.
You don't touch the ground from your seat. You stand over the frame. I don't see how you pedal at all with the seat that low. You're working twice as hard to go much slower than if you adjusted the seat correctly.
 

Yuriman

Diamond Member
Jun 25, 2004
5,530
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You don't touch the ground from your seat. You stand over the frame. I don't see how you pedal at all with the seat that low. You're working twice as hard to go much slower than if you adjusted the seat correctly.

The seat adjustment is correct for someone 5'5".
 
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JulesMaximus

No Lifer
Jul 3, 2003
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A neighbor of mine builds these as kind of a hobby. I've ridden a couple of them and honestly they're a little scary. Way more powerful than an old bicycle should be and a lot heavier. Add rim brakes and stopping and turning can be sketchy. I like the idea but I've yet to ride one where the implementation was very good.
 

Demo24

Diamond Member
Aug 5, 2004
8,356
9
81
A neighbor of mine builds these as kind of a hobby. I've ridden a couple of them and honestly they're a little scary. Way more powerful than an old bicycle should be and a lot heavier. Add rim brakes and stopping and turning can be sketchy. I like the idea but I've yet to ride one where the implementation was very good.

20mph isn't too fast, but much more than that probably gets sketchy on this style bike. The really cools ones are the pedal assist models, where the more/harder you pedal the faster you go. Some of those bikes reach scooter speeds without much trouble or too much effort. Pretty useful at commuting around without getting too sweaty, etc. They are of course somewhat expensive.
 

Yuriman

Diamond Member
Jun 25, 2004
5,530
141
106
A neighbor of mine builds these as kind of a hobby. I've ridden a couple of them and honestly they're a little scary. Way more powerful than an old bicycle should be and a lot heavier. Add rim brakes and stopping and turning can be sketchy. I like the idea but I've yet to ride one where the implementation was very good.

This one actually came with an optional pedal assist sensor, but I haven't installed it so I couldn't say how well it works. So far I can't say I'm a fan of the thumb throttle (maybe I can get a lighter spring in it?) but I didn't have an obvious place for the twist throttle.

The bike is really light. The rim + motor only weighs about 6lbs more than the old rim, the battery packs (x3) weight about 2lbs each, and the controller weighs next to nothing. I'm pretty small, and was surprised that I'm still easily able to carry it up the stairs to my apartment.
 

drnickriviera

Platinum Member
Jan 30, 2001
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I doubt you'll get 30miles w/o a lot of pedaling. I get around 20mi with my 52v 6ah pack. Think they say an avg is 15-20wh/mi. I had looked at the hub motors. The price is tempting, but I decided to go with a middrive BBS02. Did you add a torque arm to it?
 

bigi

Platinum Member
Aug 8, 2001
2,490
156
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Excellent OP.

Now, I've used EGO 56V tools and have 3 batteries. I am thinking of getting 48V kit and use batteries I currently own. The 5AH battery lasts full time while mowing .3 acre lot and is still green afterwards. I think it should be plenty for ebike.
 

Yuriman

Diamond Member
Jun 25, 2004
5,530
141
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I doubt you'll get 30miles w/o a lot of pedaling. I get around 20mi with my 52v 6ah pack. Think they say an avg is 15-20wh/mi. I had looked at the hub motors. The price is tempting, but I decided to go with a middrive BBS02. Did you add a torque arm to it?

My pack about 50% more watt-hours than yours, so I don't think 30 is out of the question. Plus, I'm almost certainly smaller and lighter.

How do you like the mid-drive? I've read good things about them, but ultimately it was price and stealth that pushed me towards a geared hub motor.

No torque arm, but the kit included some locking tabs for both sides. I'm thinking it should be alright since it's a steel frame, but I might add one.
 

Yuriman

Diamond Member
Jun 25, 2004
5,530
141
106
Excellent OP.

Now, I've used EGO 56V tools and have 3 batteries. I am thinking of getting 48V kit and use batteries I currently own. The 5AH battery lasts full time while mowing .3 acre lot and is still green afterwards. I think it should be plenty for ebike.

Only thing to watch out for is that you don't draw too many amps from your batteries. Definitely look up what they're rated for before picking out a motor.
 

drnickriviera

Platinum Member
Jan 30, 2001
2,456
266
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I completely missed that you had 3 packs. I like the mid drive. Being able to use the gearing is nice. I detuned it as it had more than enough power for me. 30mph was no problem. I wouldn't bother with PAS unless it had a torque sensor. I can go into my computer and change a bunch of the pas settings and it is just never quite right for what I want. Sometimes on the flats I want no assist, others I want lots of assist to keep in front of traffic. Thumb throttle does what I want when I want. It would probably be different if you just wanted to be lazy on a bike path.

Here you go bigi, build this. 6X Dewalt battery pack build
https://www.youtube.com/watch?v=ISR8pKoIa5k
 
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