Prepping for a eBike build
#1
S'Cruzer
Thread Starter
Prepping for a eBike build
My brother talked me into doing a convert on his '99 Trek 6000 hard tail, I talked him into a mid drive.
I've stripped his bike and am waiting for the TSDZ2 48V kit I ordered, ETA is Monday.
thats a 48V 13AH (625 watt-hour) battery pack waiting for the torque sensing mid-drive...
I've stripped his bike and am waiting for the TSDZ2 48V kit I ordered, ETA is Monday.
thats a 48V 13AH (625 watt-hour) battery pack waiting for the torque sensing mid-drive...
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#3
S'Cruzer
Thread Starter
kit was delayed, I should be getting it tomorrow... so this thread isn't dead yet
Phew, wanna make a old dingy bike look nice and shiny, wipe it down with WD40 to remove all the greasy munge, then wash it off with simple green and water to remove the oil from the WD40 and get any mud off that remains... now sure, this bike is relatively new, its a 1999, and its been stored indoors.
Phew, wanna make a old dingy bike look nice and shiny, wipe it down with WD40 to remove all the greasy munge, then wash it off with simple green and water to remove the oil from the WD40 and get any mud off that remains... now sure, this bike is relatively new, its a 1999, and its been stored indoors.
#4
S'Cruzer
Thread Starter
rest of kit arrived today.
unpacked...
I did a trial install of the main parts, still have to sort out the wiring and stuff.
the TSDZ2 middrive
the XH18 controller
I think I'm going to put it together, temporarily tiewrap the wires out of the way, and take it for some test rides, before I wrap and secure the harness.
unpacked...
I did a trial install of the main parts, still have to sort out the wiring and stuff.
the TSDZ2 middrive
the XH18 controller
I think I'm going to put it together, temporarily tiewrap the wires out of the way, and take it for some test rides, before I wrap and secure the harness.
#6
S'Cruzer
Thread Starter
#7
S'Cruzer
Thread Starter
so I put it together, reinstalled the chain and pedals, tiewrapped the wiring out of the way, and took it for a quick spin around my driveway. power is nice and smooth, at power level 2 its fairly subtle, at 3 its more obvious. I was just in 3rd or 4th gear doing circles around my driveway, so didn't get a chance to go any faster. will be taking it for a test ride later today, and see how it does climbing the hill I live on. sticking with the 11-30 rear cassette for now, and a 42T front, that gives a pretty wide gear range, spinning 90 RPM cadence in top gear should top out at about 28 MPH, be interesting to see if it and I can maintain that in the flats.
#9
S'Cruzer
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#10
S'Cruzer
Thread Starter
oh, I thought I posted a few more pics from today's 13 mile test ride...
bike with temporary wiring...
'steamers lane' here in Santa Cruz...
bike with temporary wiring...
'steamers lane' here in Santa Cruz...
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#11
S'Cruzer
Thread Starter
trigger throttle added to right bar... not a fan but my bro wants it.
gonna trim both paddles down a little so I can slide the shifter more to the right, as it is now, the shift cable is pushing against the bend in the bar, and binding.
gonna trim both paddles down a little so I can slide the shifter more to the right, as it is now, the shift cable is pushing against the bend in the bar, and binding.
#13
S'Cruzer
Thread Starter
https://www.eco-ebike.com/
I was gonna go with eBay or AliExpress, but all the sellers had single digit history and little to no options... Eco was competitive on price and offered good email support.
I was gonna go with eBay or AliExpress, but all the sellers had single digit history and little to no options... Eco was competitive on price and offered good email support.
#14
S'Cruzer
Thread Starter
so.... soldered the battery wires inside the battery mount plate (didn't like the bullet connectors it came with), and decided /not/ to cut the excess length of 6-conductor to the handlebar display/control, instead doubled it up under the downtube, and spiral wrapped it along with the splitter cable for the display + throttle...
not my neatest wiring job, but adequate.
not my neatest wiring job, but adequate.
#15
S'Cruzer
Thread Starter
took the bike for one final test ride before handing back to my brother tomorrow... rode 21 miles. mostly at power level 3 and 4. pretty easy to maintain 20 MPH in top gear on level ground, and hit 25 if you want to spin harder (42:11 top gear w/ 26x1.95 means a cadence of about 90 to go 28 MPH). my next build will NOT have a throttle, it doesn't work that well with the TSDZ2, the pedal assist is plenty good enough.
at 20 miles, the battery was still at 4 of 5 bars. at the top of the 1 mile last hill, partly 80% grade, mostly in 5th and 6th gear at 10MPH, the battery indicator was blinking between 3 and 4 bars under load, and when I stopped it reverted to 4 bars. I think this 48V 13.5 AH battery would probably take this bike 60 miles or more.
at 20 miles, the battery was still at 4 of 5 bars. at the top of the 1 mile last hill, partly 80% grade, mostly in 5th and 6th gear at 10MPH, the battery indicator was blinking between 3 and 4 bars under load, and when I stopped it reverted to 4 bars. I think this 48V 13.5 AH battery would probably take this bike 60 miles or more.
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#16
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https://www.eco-ebike.com/
I was gonna go with eBay or AliExpress, but all the sellers had single digit history and little to no options... Eco was competitive on price and offered good email support.
I was gonna go with eBay or AliExpress, but all the sellers had single digit history and little to no options... Eco was competitive on price and offered good email support.
#17
S'Cruzer
Thread Starter
yeah, I'm way happy with them.
for my own build, which I want to be lightweight, on my 700C hybrid, I asked if they could build a 13S3P pack with high capacity cells in the smaller Shark case, sure, no problem, lets use 30Q's for 10AH total, $xxx (quite reasonable), 2-3 week lead time (hey, custom build, I can't complain). They also are willing to kit me a specific TSDZ2 stuff thats not on their website (I want the low Q right crank, a 52T w/ guard, but not much else, no brake levers, no throttle, for my build).
(next project ^o^)
for my own build, which I want to be lightweight, on my 700C hybrid, I asked if they could build a 13S3P pack with high capacity cells in the smaller Shark case, sure, no problem, lets use 30Q's for 10AH total, $xxx (quite reasonable), 2-3 week lead time (hey, custom build, I can't complain). They also are willing to kit me a specific TSDZ2 stuff thats not on their website (I want the low Q right crank, a 52T w/ guard, but not much else, no brake levers, no throttle, for my build).
(next project ^o^)
#18
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Nothing like travelling 13 miles and discovering your out of shape just look down at the battery, stroke it lovingly and tell it how much more you love it than your wife
#19
S'Cruzer
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#20
S'Cruzer
Thread Starter
resurrecitng this year old thread.... my brother loves his setup. only problem its had in the year since build was the speed pickup magnet wasn't quite in the right place so it was marginal. I moved it to the correct place and it became much more robust and reliable.
So.... I finally pulled the trigger on a similar kit for my 700c Hybrid shown in post 17.... I ordered the TSDZ2 kit from eco-bikes with the 52-42 front.... my hybrid currently has a 48-38-28 triple, and a 13-26 8 speed rear (HG50-8 cassette "V", I think) I'm hoping I can leave it on 52T, adn the 13-26 (or maybe a wider range 8 speed) will be adequate with sufficient power assist to maintain a good clip..
not sure if I'll even put a shifter on the front, I might just have it as a manual, if the 52T turns out to be too tall, plop the chain down on the 42T for the rest of the ride. I'm not going to use a throttle at all, purely torque sensning, and I'm getting the version with the opensource firmware that lets you fine tune the torque/response curves. I plan on limiting the 750W motor to 500W. I ordered a slimmer profile Shark battery pack filled with 48V 14AH of Samsung 3500E goodness as I want this bike to stay on the light side so its still fun to ride.
So.... I finally pulled the trigger on a similar kit for my 700c Hybrid shown in post 17.... I ordered the TSDZ2 kit from eco-bikes with the 52-42 front.... my hybrid currently has a 48-38-28 triple, and a 13-26 8 speed rear (HG50-8 cassette "V", I think) I'm hoping I can leave it on 52T, adn the 13-26 (or maybe a wider range 8 speed) will be adequate with sufficient power assist to maintain a good clip..
not sure if I'll even put a shifter on the front, I might just have it as a manual, if the 52T turns out to be too tall, plop the chain down on the 42T for the rest of the ride. I'm not going to use a throttle at all, purely torque sensning, and I'm getting the version with the opensource firmware that lets you fine tune the torque/response curves. I plan on limiting the 750W motor to 500W. I ordered a slimmer profile Shark battery pack filled with 48V 14AH of Samsung 3500E goodness as I want this bike to stay on the light side so its still fun to ride.
#21
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Not sure what a thumb throttle is like on that particular set up but I wouldn't be without one on my Bafang. Really comes in handy when sitting in the left turn lane of a busy intersections and wanting to accelerate with the rest of traffic when the light changes.
I installed a brake cut out but can't say I even notice that doing much. I do really like the shift sensor, that works beautifully. Maybe a shift sensor isn't as necessary with a torque sensing unit like it is with a Bafang.
That Trek is a near perfect ebike candidate.
I installed a brake cut out but can't say I even notice that doing much. I do really like the shift sensor, that works beautifully. Maybe a shift sensor isn't as necessary with a torque sensing unit like it is with a Bafang.
That Trek is a near perfect ebike candidate.
Last edited by Pop N Wood; 09-21-20 at 04:10 PM.
#22
S'Cruzer
Thread Starter
I figure I can add the shift sensor, but I didn't use one with the Trek install... that install DOES have the thumb throttle, when I rode the bike I found it fairly useless. The TSDZ2 torque sensing is a thing of beauty, its an almost seamless riding experience when properly dialed in.
#23
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That is so cool, I'm jealous! :-)
I'm thinking the only time you will need to use the small chain ring is if the battery goes dead. ;-)
I'm thinking the only time you will need to use the small chain ring is if the battery goes dead. ;-)
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Either it's the terrain I ride (very hilly) or obtuseness, but my BBS02 doesn't feel as though it's "kicking in" or "out". Almost all the time it's the choice to ride over a Yahama- equipped Haibike, both hardtails with similar equipment, and the Yahama supposedly having torque sensor, RPM sensor and bike speed factored into the level of assist. Maybe the BBS happened to be adjusted perfectly by the vendor since I haven't neither performed any maintenance nor adjusted anything in the five years+ that I've been using it off road.
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#25
S'Cruzer
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so my hybrid.... currently has some really nice older Vittoria Randoneeur Hyper or Pro or something that are very high thread count, 700x32, and quite light and supple for their size, yet have decent puncture resistance.... these tires are 6-8 years old, and getting tired (groan!) so, I'm thinking with 500 or 750 watts of zoom, I should get something new, and I should probably go to x35 or x38's... I eyeballed my frame with a caliber, I think I could go as high as x45's without issues. I'm having trouble finding hybrid sizes (700x35, x38) with high thread counts. I guess I could go to Schwalbe Marathon HS 440 or something, any comments on this?
I'd actually like to go disc brake, but while my frame has the bosses for a rear disc, my forks don't, and the forks match the frame nicely now.
also, I'm thinking of dumping the 8-sp derailleur in back and going to a Nexus 8 speed hub, with new wheels... 36H, V-brakes. i'd still prefer sticking with trigger shifting, and yes, I know, getting the chain sizing and tension right on a non-single-gear frame is annoying.
I'd actually like to go disc brake, but while my frame has the bosses for a rear disc, my forks don't, and the forks match the frame nicely now.
also, I'm thinking of dumping the 8-sp derailleur in back and going to a Nexus 8 speed hub, with new wheels... 36H, V-brakes. i'd still prefer sticking with trigger shifting, and yes, I know, getting the chain sizing and tension right on a non-single-gear frame is annoying.