Ready to RIDE!

Needed to send back my seat shock I ordered (needed 27cm version not the 31cm version) and will need a gel seat but then I should be good to go.  After I get a chance to take it on longer trips, I will report back on how she performs!

Second ride - 5 miles

Here is some video from my second ride.  This time I did the video shooting, riding and working the throttle.  I was able to get up to about 20 MPH on a flat stretch.  It also was helpful climbing the hills around the neighborhood too.  When I started I had about 3/4 of the battery left.  Was down to 1 bar when I got back home. 

First Test Ride!!

Thanks to my wife Nadine for the camera work.  I was able to get up to 28 mph before turning around.  I was just getting to the top of the hill and I'm sure I could have gone faster if I kept going.
After this little bit of riding, batteries still showed full.  I will update with how they perform once it gets warmer and I can do a proper ride.

Finish Wiring

I used a small bag to house the wires in the space between the battery and the controller.  Will not be water proof as it sits, but I'm not going to be riding in the rain if I can avoid it.  Below is right before my first test ride.

Mounting controller and battery

Took a bit of doing but I was able to zip tie everything to the frame.  I used some foam window insulation between the controller and frame where they met.  Idea is to stop any rattling.  I was able to fix the battery in the open space just under the frame pretty well.  I was able to run the wires down the frame pretty well.

Handlebar Work

2/19/2018 Mount Display and Accelerator

Took apart the right side handlebar by sliding everything off.  A bit of compressed air under the grip helped.  After that slid everything back on starting with the accelerator.

I marked the bar for where the brakes and gear shifter were originally mounted.   That way the cable lengths didn't need to be adjusted and the stock grip fit back on correctly.  I decided to not change out the brake handles at this time.  The ones from the kit have shut off's built into them.  Since I am not using the PAS system at this time, I don't see the need for this.  I will just let off the accelerator when I engage the brakes to stop.  I can always install later if needed.

I also connected everything and did a test.  Everything worked as expected! 

I next modified a few of the settings in the display.  Changed the ODO from KM to Miles.  Also changed the default power mode to accelerator only from combo PAS/accelerator. 

Start Building

Unboxing, Mount Motor, Build Battery

Mount Rim/Motor
Next came mounting the motor to the front fork of the bike.  To do this I pulled off the front wheel that came with the bike, dismounted the tire, tube, and brake rotor and mounted them on the new rim with the hub motor in the middle.  There was a spacer provided for the rotor but I needed to remote this in order for it to fit my brake setup.  I then mounted the wheel and adjusted the disc brakes and tightened everything up.  After a bit of adjusting, the wheel turned freely and the front disc brakes worked like a charm!

Build Battery
After unboxing everything, I started by building the battery.  I connected the 3 12v batteries in series (Pos - Neg) to obtain my desired 36V.  I then used tape to physically connect the batteries into a pack that is 10 1/2 x 2 3/4 x 4.  Checked the charge and they came fully charged!

Getting Started - Ordering/Purchasing

Been thinking about and researching for years.  Hopefully this will be the first of many ebike builds!

I may shoot some video too, but for now I wanted to document the parts list and experience putting this together.  I will also sprinkle in some thoughts about things that worked well and not so well along the way.

2/13/2018 - Started ordering / purchasing parts

Balancing Weight vs. CostThe thought in the back of my mind as I selected various parts and options was to strike a balance between overall weight for the bike and keeping cost down.  I suspected to learn many things during this process so in a way this is a prototype for me.  As such, when I needed to pick various components, I used this thinking to guide me.

Bike $129:  26" Men's Kent KZR Mountain Bike, Black 
Was looking for aluminum frame and front disc brakes.  Seemed like 26' was the most popular ebike kit option and my existing bike had that size tires so I went with that size.  We will see if this bike overall is big enough for me (6' 1", 250 lbs).  In hindsight, should have gone with next step up (700cc).  Was also looking for front suspension at a minimum and needed room to mount the batteries in the middle of the frame to keep weight balanced.   

Ebike Kit $185: ELECTRIC BICYCLE 36V 500W GEARED FRONT 26” KIT (OPT2)
Was looking for a front mount, geared motor.  Thought 24v would be too small but 48 seemed like too many batteries to mount mid frame.  If I was going to do a back tire rack, I may have gone up to 48v.  Was also trying to keep weight down so this motor was lighter and 1 less battery helps too.  We will see if enough power for me.

Batteries $48: 12V 5AH SLA Battery Replacement for Razor PowerRider 360 
Went back and forth about SLA vs Li-ion.  Went with small SLA batteries to keep cost down.  I suspect I maybe upgrading to Li-ion or using them on the next build.  Since this is a learning experience for me I didn't want to spend the money now.  I also am not planning to use this bike daily or to commute or anything so that was in my mind too.

Charger $30, 36V SLA Charger SLA AGM GEL

Bag $13, Bushwhacker Laredo Black - Bicycle Frame Bag 


Seat Pole Shock $29, Choose Suspension Seat Post 27.2 x 350mm 31.6 x 350mm 

Total cost: $434 plus tax

Links  

https://www.walmart.com/ip/26-Men-s-Kent-KZR-Mountain-Bike-Black-Red/47443516#read-more
https://www.ebikeling.com/shop/electric-bicycle-36v-500w-geared-front-26-kit-option-2
https://www.amazon.com/gp/product/B00VH5ABVU/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B072Y19QWQ/ref=od_aui_detailpages00?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B0091UCYHM/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B06XCBSHGF/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1