High powered DIY eBike MSVA build part 9 - DIY lithium battery build woes AGAIN
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- čas přidán 6. 09. 2024
- This is my 3rd build which is now an e-motorbike and no longer a normal e-bike.
It's going to have number plates because I'm putting it through the MSVA.
Please consider supporting me on Patreon / vortecks
You get to see my (sometimes) daily progress and some very 'juicy' and uncut bits that I daren't show here. Also, you'll get my support if you support me!
There's a reason why I'm building it with a removable batter - WEIGHT! Carrying a pushbike up 2 flights of stairs is bad enough but when it weighs in excess of 40kg and you're in your 50's, it really does take its toll.
I won't be listing prices as they change dramatically with China.
Parts shown so far:
VBMS app is available on Google Play play.google.co...
The wheels are 18x1.6 and come off a CZ250 motorcycle. eBay is full of them - ebay.us/uxpXH8
The tyres are Mitas MC11 2.50-18 www.bits4motorb...
The BMS can be bought from ALIExpress s.click.aliexp...
Batteries (LiitoKala Lii-50A) are available from AliExpress s.click.aliexp...
Silicone cables www.components...
Nickel strip (pure nickel) ebay.us/AB5Zre
ISDT C4 charger I use to balance the cells (video review) www.youtube.co...
ISDT C4 charger link www.banggood.c...
84V 9A Charger s.click.aliexp...
Neutrik Speakon connectors ebay.us/WEyqpo
12G spokes s.click.aliexp...
Neoprene (50mm x 3mm) amzn.to/2RUNF3d?
Aluminium heat sinks that I use on the BMS www.banggood.c...
Items in this video: • High powered DIY eBike...
Item 1 goo.gl/UX5YJd?
Item 2 goo.gl/QnAXty?
Item 3 goo.gl/VTw6xz?
Item 4 goo.gl/8kBzwo?
Item 5 goo.gl/YzyVtp?
Headlights www.banggood.c...
The handlebar switches I now use www.banggood.c...
Real filament PETG black amzn.to/2TVivGg?
Domino throttle fasterbikes.eu...
Carbon fibre - Don't be fooled by cheap eBay sellers. You want it to come in a rolled tube so the weave doesn't get distorted.
1000 x 350mm 2x2 Twill Weave 200gm goo.gl/ 1nxD4D?
1250 x 500mm 2x2 Twill Weave 200gm goo.gl/vUTZsf?
3000 x 1000mm 2x2 Twill Weave 200gm goo.gl/zjjgYR?
Resin & hardener goo.gl/tFW3Su?
Magura MT5e brakes goo.gl/q4UUq3?
Carbon fibre handlebars s.click.aliexp...
Red LED lights www.banggood.c...
The headlight I bought from this seller - don't buy from him because he offer next day delivery but sends it via 2nd class www.ebay.co.uk...
Horn (black one) goo.gl/r3JSgv?
Horn (multi coloured) goo.gl/unJkzk?
72v to 12v DC-DC converter s.click.aliexp...
The 'expensive' motorbike handlebar switches goo.gl/sGzygY?
Indicators ebay.us/PRwEmv
Fork clamps ebay.us/zS8YXr
Rear tail/brake light ebay.us/8Njfyk
Hope V4 Caliper goo.gl/gh8pnt?
Hope vented floating front disc rotor goo.gl/s6EGqA?
Koso EX-02 Speedo bit.ly/2JvMyUr?
Koso GPS module bit.ly/2FvGAz5?
Here's the link to my DIY strobe light www.youtube.co...
12v 8 channel relay www.banggood.c...
Arduino sketch for lights drive.google.c...
Seat post ebay.us/asJGYt
LED indicator panel lights www.banggood.c...
Mirrors ebay.us/gisOD3
Mirror bracket ebay.to/2XJfhYm?
GPS speedometer - 35mph version www.banggood.c...
GPS speedometer - 80mph version www.banggood.c...
Waterproof automotive connectors www.banggood.c...
30W 9-85v LED headlight www.banggood.c...
Side stand s.click.aliexp...
AS150 (Anti-spark) connectors bit.ly/2Khv3qR
I almost cried watching you disassemble your batteries! There is always the unthinkable....cut the downtube and headtube and extend the frame for a longer wheelbase, so the batteries fit inside the frame. I did this on my mongoose fatbike frame, and it hasn’t broke yet🤣.....but I don’t want to be packing it up any stairs. I ran out of battery 6 miles from home on a backroad with 2” of loose dust/sand on the surface. I nearly died pedaling it home....pedalling a 110 pound bike with 4.5” low pressure tires in deep dust is NOT reccomended, lol.
I have a low powered Ebike conversion based on a Mongoose Alta. I haven't weather proofed the wiring yet so in the wet it cuts out. It would be easy enough to pedal home on tarmac if it wasn't for the single speed conversion.
hehehe! I can relate to that very well too! :-)
I am a man of persistence and innovation. If I get parts and they don't fit, I keep trying until they do and I refuse to alter things (I suppose it's a mild form of madness) 😂
Vortecks I can appreciate that...I think you could build a bike from the wheels up too, if you so desired!
@@jimhofoss9982 I can also build wheels 😁
Well, at least we learned how to build a bloody big battery!!
....next week, you'll learn how to build one that fits!
I just love how much the quality of your videos is improving.
Tv needs what this guy has....Tv needs this guy
Tony.
Instead of struggling to wrap the batteries around the bike frame. Why not alter the bike frame to accommodate the batteries? I know its probably not the sort of thing you would normally do but its not too difficult.
Split the top tube, use 2 smaller diameter tubes instead of one large one, then slip in between them a slim designed battery. They do something similar with petrol tanks on motorcycles.
I am a man of persistence and innovation. If I get parts and they don't fit, I keep trying until they do and I refuse to alter things (I suppose it's a mild form of madness) 😂
I made a plastic box and put my battery in that, then I used loads of zip ties holding it to the DH forks, it honestly so strong I would put my dog in it! Haha
Oh man... that's just tragic - I think I would have saved up for some more batteries and build fresh, and having the previous set as a auxiliary battery or home battery with inverter etc.
The trouble is, Andy - the battery is the heart of the build and I need to get it done to progress any further. It'd take me 5 months to save up and another 2 months for the batteries to arrive so I had no choice.
@@Vortecks I know, would take me months to save up too so know how you feel between a rock and a hard place. Maybe with the new plan you can use some of the space inside the frame triangle as well. It's a really challenging 3D jigsaw puzzle and maze guaranteed to do your head in... but an awesome achievement when successful!
Tony, I admire your tenacity and ability to innovate solutions to problems. Looking forward to seeing this project progress toward completion.
Cheers, Bob. I haven't seen any video from you lately, is the bike still going strong? I did enjoy your attention to detail though.
do what i did..build your own delta style recumbent tricycle...my SLA battery series weighs a total of 38 pounds but with 750 watt 48 volt motor- i do not even notice ( i did have to rig breaks for all 3 wheels) .
That’s unfortunate. Lots of welds again...hope you don’t go insane. 😜. Main reason I am taking my time to do mine just right so I don’t have to donut more than once. I don’t even have the nickel yet so that is helping me not to just jump into building it and taking my time. Hope your build goes well. Still a lot of battery to slap in the side of that frame. Can’t wait to see it go...again.
You got this Tony - abandon the linear parallel groups and eat a little discharge imbalance, go with a non metallic custom enclosure and to hell with 'boxes'. That's beginner thinking and the V2 showed your no beginner.
Vent holes at the front of the case so flame is away from your legs if any thermal runaway? (Filling cell-to-cell and cell-to-case gaps with something thermally conductive and fire retardant might help cell cooling?) -- with flame vent pathways
i think you were trying to say grease the threads LOL keep up the good work love your videos, and its great to see a local guy doing this, as i am just up the road in Rugeley.
I lived in Rugeley from ages 7-13 and I still go through there very regularly 😁
Ouch Tony, painful to watch that all coming apart :( Question: surely that will make it more of a nightmare to connect up with cells running parallel to the top tube? If you do, I’d recommend as you showed two cells and another between.. then I’d add another two on the opposite side (making a patten of five in a star shape ‘viewed on end’). If you get what I mean. This would maximise the available space but no idea how that would be wired up.
Or, make a pack that fits the space using cells 90deg to the top tube in a big block like you had it and maybe a pack either side in very slim removable panniers (cells running parallel as shown in your drawing) only one cell thick each side. Just some ideas Tone, good luck fella
Oh shit who put that 2 gang socket on the top of skirting board 😂😂😂
Why don't make you fist a nice mount where you can slide the cells in that also fits the bike? Than you can use that mount also to put the cells in for welding.
I know it's been said before but it's a shame a pannier cannot be supported on this frame. Tbh if it did the front end would have trouble staying on the ground which reminds me of a rc car I used to own with the battery at the rear lol
Could you build the battery case shaped like a wind deflector like the Honda C90? It would protect your legs a little and look batter than most e bikes with bulky cases. Just a thought. Great work so far.
Yes but..... it would then look like a Honda C90. I'm trying to be 'low profile' so I don't attract attention.
Hi Tony, I never get tired of watching your videos I cannot wait for the next one. I have a propersision for you , how do you fancy finishing off my e-bike build? It's all built apart from connection of the Sabvoton and the cycle analyst? It's really giving me a headache now and have no clue on how to connect it up? I live in Bristol and I don't mind bringing the bike to you ? Obviously I would pay you.. Cheers Gary..
hey there vortecks, in one of you previous videos I sugested cheking out the new flexible batteries, these do not seem to be as strong but they are safer, a lot safer, and they can be bent into odd shapes, it may be posible for you to add them into your build, I imagine that you could take advantage of their flexibility, they potentially will grant more ways to spread the set up, thus potentially you would get a slimmer product
I've already got all the parts I'm going to use. I'm a persistent and innovative person who won't back down on something and I will make these cells work for me 😁
Please don't take that as an insult, I do appreciate the opinion of others but I'm determined to make this work.
Only one solution.. Install a side car just for the cells lol
Can you imagine carrying a 15kg battery in a backpack?
@Walter Sobchak clumsy solution
@Walter Sobchak batteries are expensive custom ones even more so. He wants the bike as light as possible and less awkward as possible
@Walter Sobchak not the point. Having s back pack would be clunky and sweaty in summer and having to keep connecting cables more hassle than its even worth contemplating. Vortecks had been doing this stuff for years he knows what's best for him
proper preparation prevents piss poor performance. Keep trying Tony. you are doing a fantastic job buddy. i am just pricing up a build as well and haveing the same planing problems as you.
The hole for the inner tube stem looks sharp
Gaffa tape
could of maybe rotated them before disassembling although the finished look wouldn`t have been good. have built a couple to fit inside a frame is complicated to get head around the series joins at first.
Are you still sure after fitting them the same size has the frame you are going to get pedal clearance when your feet are on them ?
Good work, gonna be a beast when you finish it 👍🚲
I think the new battery pack idea is going to be much better than the old one Tony. Will u end up with the same capacity? Even if its a smaller pack it will be much more streamlined and look so much better. The weight will be much better distributed to. Wont feel like u are trying to get a baby whale round corners so much lol. Happy new year mate have a good one
It'll be the same capacity. It's turned out really well actually, I just need to figure out how to mount the bloody thing now!
Oh..... Happy New Year to you too mate 😁
Oh Tony mate i have the same syndrome as you!...build it well first time then pull it apart for an oversight ;) ...great vids and highly entertaining!!!
Well, that was a bit of a fecker !
In the plan for the new battery configuration in the triangle, did you allow for the full movement parameters of the suspension ? Or are you not going to use the inner part of the triangle and leave it as a void ?
I thought you were going to use a Dremel to clean up the old welds.
The triangle will be a void.
I can't use a Dremel to clean the welds - the battery is very thin nickel coated steel and spot welding to steel is rather messy.
@@Vortecks - Do you think there is anything that could go into the triangle ? Maybe the BMS ?
Keep up the good work Tony. I hope you overcome all of the design problems you're encountering.
Seasons Greetings and a Happy New Year to you.
@@herenow2895 Yeah, I have plans for that bit but there's no way will the controller fit in there 😁
i just found that my 3000w hub doesnt fit on my bike... my bike has plates that bolt to the chainstay,which also hold the derailer... FAAAAAAACK! now i need to cut the plate so the 22mm bolts fit... gonna have to add a single speed cog too... Arrrrrrrh! (Leicester bloke)
Oh no, the Battery is in bits...Why dont you use a piece of plywood instead of Alum Tony, lighter, easier to cut and the cells cannot short on it...?...I think you should have opened out those spoke holes in the Hub a little bit maybe..?
Quad building is so much easier....lol.
Plywood swells, delaminates, deforms and cracks mate.
You're right, quad building is soooooooo much easier and sometimes, I wish I hadn't started this bloody thing 😁
Is there no way you can have the batterys on either side of the back wheel like how some of the motorbikes have storage on the sides?
Nope, I've spent many hours looking at it and it would take some serious engineering to make something and it'd weigh too much. The rear suspension is the killer and also, I need as much weight up front as possible - the old one used to wheelie too easily.
@@Vortecks only other thing is hang it over the front bars in a basket 😉
Mount the 2 aluminium boxes sideways and stepped.
tbh I dont know if its possible to get a battery that big mounted to the frame and still being able to pedal.. I built an electric bike around a downhill frame with 8x16000mah Tattu 4s (the same cells which u used before). At first I also tried everythig I could think of to get the batteries as close to the frame as possible, so that I have enough room to use the pedals... But as the built went on, I saw that, for me, there was no chance to use a battery that big (1,9kWh) and still being able to use the pedals. Now its more or less a light and powerful motorcycle, without the option to pedal, but thats fine for me. ...I just want to say, maybe you think of a plan B, just in case big battery + pedals do not work out for you.
One idea that worked for me: Use aluminium u-profiles and bend them in the shape you need. Than use CFK plates on both sides (Like a sandwich), that way you have a light weight box that is relatively durable.
It's a 2.5kWh battery and I *WILL* make it fit 😁
Grease them nipples! Haha. Going to be a monster that bike. Will the boxes fit vertically just for a little bit more leg room? Either that or your going to have to build a nox to fit in. Good luck cant wait to see.
Good vid what about a backpack battery.
33lb on your back.... does that answer the question? 😁
@@Vortecks Ive got 6x6s 12AH multistars in a backpack and the backpack itself is very heavy to move around but once its on my back it isnt too bad only really feel it toward the end of a longer ride than my 20 min commute ( i have pretty much the identical frame to you)
Great video Tony!
I've used dry film lube on those juvenile nipples and spokes. It is a bake on process. 10 ga? I recall you saying 12 ga before.
The front are 12g, the rear are 10g.
@@Vortecks massive!
happy new year brum 👍
And you mate 👍
Have you thought about doing the red bull soap box challenge? 😀 I think you should. Also, what camera and mic do you use on the bike? I have a motorbike but a rubbish camera and wind noise.
I couldn't do it, I'd want to put some 'illegal' things in there to beat the competition. If that failed then a flame-thrower would be my backup.
The camera install video is here...... czcams.com/video/E2gG-vhM2RI/video.html
Poor thing! Hated to watch you take the battles apart!
Sadly, it had to be done 😒
Pannier packs would have been so much easier..
....and so much more dangerous. It's not possible to fit a pannier mate - it's got rear suspension and there's nothing that can handle the weight.
Plus which, I need all the weight up the front because V2 used to lift the front wheel very easily - with the weight over the back wheel, I wouldn't stand a chance.
You should check out Robert Murray Smith for your battery build
What battery cells do you use? 👍
versatec1 he has them listed in the video description
Thanks 😁👍
hi tony ! if you have a 3d printer , print a custom case specifically design to your dimensions,,,,,,thanks tony
Already ahead of you mate - I've been designing :-)
@@Vortecks sorry ; but that was just a simple idea !
@@ricksquebecrc4627 The simplest ideas are always the best!
@@Vortecks true !
yeah the pulling grapes method is the best for removing batteries from strings..
I just want to know if that brand of IMR cell chemistry will stand the test of time? When I added mineral oil 1k hub was a huge difference terms of less friction. As ever another great video.
Probably not but I'll have some fun finding out 😁
Brilliant, and we all will equally enjoy the journey. Have a good New Year.
tony...my new battery came... 72v 30Ah... it came with a friend... another 72v 30Ah battery! bastards took for two and sent two when i wanted one! arrrrrrh!.... my bike goes like shit off a stick! dare not full throttle it after i hit 67.8kmp... foooooooooook!
So, you have 2 batteries? I thought that kind of shit only happened to me!
Lol... I think it happens to every westerner who orders from China. 👍
You are the best
Thanks :-)
What's the point in peddling anyways, exercise baaah humbug!!
I feel your pain 😂
always good to oil the nipples :Dif you dont have oil or grease can also use vaseline :D
Cool vid ya blind git ,shame the batterys dont fit ,good luck with the next
Yeah, it's a bit of a bugger but hey ho, it's all in the name of science mate :-)