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60V 3000W Fat Tire eBike - Big Battery Build 3.4 kwH 100 mile+ Range

Wrench

Well-Known Member
Joined
Nov 14, 2018
Messages
1,601
you want me to ride 100+ miles. the battery is 3.4kwH. at 30mph that is 1kW (probably lower for me) for 3.5 hours = 100 miles. Also, at 20mph that is 500W so 6.8 hours = 136 miles. Take 10% as a reserve and that is 90 miles at 30 mph and 123 miles at 20 mph. dont worry i will do a real world range test. also this is on a fat bike so lower efficiency but im a light rider so i think it balances out.
100+ miles no problem, just go with pedal assist @ 10 to 15mph for 10+ hrs like b basset :ROFLMAO:
 


CrazyDan

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Joined
Jul 9, 2016
Messages
2,842
One 10s brick is done. Not bothering with balance leads for now till I get some more plugs in the mail (did the bottom 4s). Gonna take a while for a pack this size to go out of balance. All cells measured 3.49/3.48v.
Sounds like you are getting it done the proper way.
 

bakaneko

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Joined
Nov 16, 2015
Messages
1,440
okay, i got the bb, motor, and controller positioned and installed. the negative terminal on the motor is a bit rusted so i need to clean that up a bit. i tested the motor and alignment with the old 36v battery and it seems fine. the motor is a bit off centered but its not that off. so i think its fine. you would think the second time it be easier to install...

next is the battery install. it will be two blocks in the frame and two blocks on top. there are two design challenges here and a minor one. the two are it has to be removable not super easy but easy enough that I can move the batteries inside without taking apart the whole battery mounts. the other is the top batteries is just gonna sit on the top tube and will rotate around that axis. so i think i will just make a large shim between the bottom and top batteries to prevent the top from rotating. the bottom one is going to be a tight fit so it would be solid. the other minor item is the battery box. I think i am going to use 1/4 white particle board paint one with orange accents. i need to reflect heat as much as possible. so at minimum i will do particle board -> packing foam. or, i might do particle board -> packing foam -> particle board.

lots of irl stuff to do too. so, i hope to get a good part of the battery mount done by monday and into next week finish the battery box and spiffing it up. i hope to get it all done by next weekend. :unsure:

Also gonna leave the handle bar as is for now. and the PAS will wait until Luna has their three speed switch in stock. It looks as the throttle and PAS might not work as same time so the three speed switch will be key.
 

bakaneko

Well-Known Member
Joined
Nov 16, 2015
Messages
1,440
Well, I got the battery mounted and did a small test ride. I need to clean the terminals as I think it limited some of the performance (50% SOC). It is together though and ride-able. It is hard to pedal a heavy fat tire bike with a 44T pedal cog, LOL, even in 1st gear. :ROFLMAO:

Things left to do. I hope to have it ready for next week all spiffed up.

- Clean the negative terminal on the controller; it is rusted and I feel is messing up the performance of the bike.
- Install a white main color/orange decal battery enclosure/box so it doesnt look like I am riding with a bomb. Gonna try to go for a Ford GT Baby Blue and Orange with white look or homage
- Weather proof the connections and clean up wires
- Cut 2-3 inch per side off of the handle bar to increase aero
- Buy and install speedo, headlight, rearlight and rear rack
- Charger

 

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Don_Parsons

Well-Known Member
Joined
May 6, 2020
Messages
825
Clean up battery terminals electrolyte compound will prevent corrosion... 👍👍👍

Whats the weight of these battery packs when there bunched up...

What a neat ways to make a battery ... 👍

Are those individual cells brand new or recycled...

Dang,,, I'll have to start thinking electric bike this winter...

And,,,

Can a person separate the battery packs too place in different area of the bike,,, or other words,,, fitted down low in the V of the frame,,, that way there out of the way,,, and the mass of weight is kept lower 🚴‍♀️💨

I think these bikes come from Denmark
20200715_100754.jpg


$1700 Cnd funds,,, 3 year unlimited warrant,,, not the battery,,, a 50 + mile range ...

They fold up real small too pack away,,, i was suprised how ridged they are on the trails...

My old school fold up bike is a wet noodle,,, dangerous too ride at any speed... Ha
 

bakaneko

Well-Known Member
Joined
Nov 16, 2015
Messages
1,440
Clean up battery terminals electrolyte compound will prevent corrosion... 👍👍👍

Whats the weight of these battery packs when there bunched up...

What a neat ways to make a battery ... 👍

Are those individual cells brand new or recycled...

Dang,,, I'll have to start thinking electric bike this winter...

And,,,

Can a person separate the battery packs too place in different area of the bike,,, or other words,,, fitted down low in the V of the frame,,, that way there out of the way,,, and the mass of weight is kept lower 🚴‍♀️💨

My old school fold up bike is a wet noodle,,, dangerous too ride at any speed... Ha
The batteries are suppose to be never cycled, cosmetic defects. A YouTuber used them and tested the capacity at 1.5kW on a 6kWh pack he built and it was 100% capacity. The batteries are about 25lb for each module so 50lb in total. Yeah, the way I did it maybe over kill but this is a 16s pack in total (60V nominal) that I separated into 4x 4s packs with their own 4s 60A BMS. The top tube has 2 and the triangle has 2. This is necessary as there is no other way to fit it on the bike with good balance unless you cut the top tube and do a whole fabrication/assembly thing. Apparently, you dont even need the BMS. Since the packs are separated I do like once a month probably check each pack and equalize their voltages if there is a difference. Ideally, you just build one 16s pack with a beefy bms. I might add another 4s on there and get it to 72V since I got the chargers and everything but she is a big girl atm.

I cut the handle bar and probably removed a bit too much... It is like a bobber now! At least I am aero... :ROFLMAO:

The retail ebikers range are suspect at best and require pedaling at slower speeds. There is no replacement for displacement but in this case capacity. Total cost is about $350 for bike, $450 for batteries and bms, $100 to remove the Cyclone motor from my old bike and onto new bike (some cosmetic as I broke the screen on throttle of old bike but it still worked). Probably another $20-40 for building battery enclosure and nice alien type headlights, mirrors, and rear light.
 

Don_Parsons

Well-Known Member
Joined
May 6, 2020
Messages
825
I hear yha...

They claim 50 miles,,, but thats a long shot """if""" they conditions are right...

New technology is on the way,,, a few more years will be a real game changers...

The push for heavy industry machinery is underway,,, Team Green is working on a farm tractor along with other manufacturers...

Heavy batteries are ok for our farm operations since it keeps the tractors planted on the ground,,, more weigth equals better traction and pulling power... 👍...

Not for our power bikes though
 
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