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Anyone want to share some DIY ebike builds?

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Anyone want to share some DIY ebike builds?

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flag 09SXtrail
Posted: Sep 28, 2021 at 11:19 Quote
Wanted to start a thread showing off some DIY ebike builds and maybe have some discussion. A bit surprised there was not already a thread.

Frame:

2015 Chromag Rootdown
-135 x 10mm rear drop outs
-68/73 bottom bracket (external bearing cups)
-29 inch wheel size
-Integrated derailleur hanger
-180mm Sram centerline brake rotor

Components:

Fork
-2009 Fox 34 Talas with Float spring set to 140mm
-203mm front SRAM centerline Rotor

Cockpit
-DMR 35mm Stem 50mm length
-Spank Spoon 800 with 60mm rise
-Magura MT5e with 3 finger 2 pin Higo connectors and harness
-KS 100mm dropper post with Topeak Aero Wedge saddle bag
-Ergon eMTB mens saddle with Topeak mounting clip
-DMR death grip lock-on grips

Group set
-Box Two Prime 9 group-set for ebike (one click gear changes only)
-Lekkie 42 tooth narrow-wide chain ring with Lekkie drive plate

Motor and controller
-Bafang BBSHD 1000w mid-drive motor
-SW102 display
-Main harness replaced with 2 pin Higo for Magura brakes
-52v 17.4 Ah battery with Samsung cells
-Left thumb throttle

Wheelset

Front
-IBIS 941 29" with Hydra straight pull aluminum 28 spoke hub

Rear
-eBay 36 hole carbon hoop with DTswiss 350 (12 x 142mm) Hybrid 36 hole hub with 2mm J-bend spokes
(281mm, three cross)
-Bolt-on 12mm to 10 mm step-down axle
-DTswiss 135 x 10mm hub endcaps
-29 x 2.5" MAXXIS Hookworm tires set up tubeless but running tubes

This bike is still being built up with a few parts still on their way. Most of my parts have been coming in from Europe as getting NOS items is pretty much impossible in the current market.

Current state of the build:

Frame bought here on Pinkbike

44mm headtube with frame protection.

Where it sits waiting for my stem and brake handles before wiring can start

2015 Chromag Rootdown 29er frame

Lekkie drive plate BBSHD with 42 tooth narrow-wide

68 73 bottom bracket BBSHD with Lekkie drive plate and 42 tooth chain ring

DTswiss 350 Hybrid with Box Two Prime 9 cassette

DTswiss 350 Hybrid 12 x 142 with 10 x 135 end caps and 12mm to 10mm step down bolt on axle.

Topeak Aero Wedge, left thumb throttle, Ergon eMTB saddle

Fox 34 Talas with Fox Float spring set at 140mm.
flag notsosilentbob
Posted: Oct 3, 2021 at 5:58 Quote
Good idea for a thread. It would be nice to see people posting their bikes to see how compatible various frames are with motors and batteries.
I like your build! Imagine that's great fun:-)

Here's the wife's bike...
My old 16" jump bike with a Bafang bbs02 750w and 52v battery which just fitted into the frame. I've been using it lately because I'm still mid build on mine and have to say it's an amazing little bike for belting round the woods on. Great fun and would recommend the bafang to anyone who wants to dip their toe into ebikes.
photo

Still building the battery for mine, but she's an Intense M1 , 5th element shock and 2012 ish boxxers. Currently wearing Halo twin rails for testing but will be putting some knobblies on soon. The motor is a cyc stealth.
photo
flag 09SXtrail
Posted: Oct 7, 2021 at 11:48 Quote
notsosilentbob wrote:
Good idea for a thread. It would be nice to see people posting their bikes to see how compatible various frames are with motors and batteries.

Agreed! That M1 is awesome! Will you be carrying the battery in a pack for it? Not familiar with that motor either, cyclone? I also did some Magura MT5e's on mine and ordered the HiGo pinned levers from Germany. This is my first set of Magura's. I still prefer my Shimano Zee's over them but, the stopping power is good and the brake bleed wasn't too difficult. I also like mineral oil over the DOT stuff. Looks like you have some sort of SRAM brake on the rear still.

I think the BBs02 is the best way to go bang for buck, if you are going Bafang. If you don't want to tinker or fool with beefier components, it's a great choice. I like that you went 52v as well. Looks like my same battery and I get 35+ miles pretty easily with it.
flag 09SXtrail
Posted: Oct 7, 2021 at 11:58 Quote
Chain line still a bit too far off on the 50 tooth cog. Nothing I can really do about that with this frame though. I'm about as far in as one can go offset wise. With the Lekkie 40 tooth and drive plate. Sit's about 1mm from the chain stay.

Almost done with the Cromag build


Box makes some really strong stuff. I housed the gear shift sensor in some heat shrink for a more finished look on the seat stay. Went to a 10mm thru axle on the 350 hybrid. A bit of a learning curve adapting a 142 x 12mm to my 135 x 10mm drop outs. Happy with the final results though. It's super strong and really stiff. That is an ebay carbon fiber 36 hole rim with some 2mm spokes. Bit heavy but no issues taking the torque.

Box 2 Prime 9 groupo

Also put on an Outbound headlight for some night riding. I have a mount on my mountain rig as well for those fun night trail rides. This light is fantastic for being a self contained unit. The passthrough USB-C port is awesome for those longer rides. Daytime strobe very visible as well.

I am also in the process of routing the wires through the headstem with a ONE-UP retention system. It's not made for this, but I think it will work out well and give me a clean install. I went to a DMR 35mm stem with 800mm bars with a 60mm rise. Trying to get a bit more geo out of it.

Outbound headlight
flag notsosilentbob
Posted: Oct 8, 2021 at 6:02 Quote
That's looking sweet, it's going to be a flying machine with those slicks:-)

photo
We made the battery, 21700 3/14 52v which is just duct taped on for testing at the moment.
The rear brake is a four pot Shimano
Motor is an x1 stealth from cycmotor.com who have been very good. More than enough grunt for me at power level two out of five.

Brothers bike, 2016 gt fury in xl. Same motor but with a 4/14 battery pack.
photo
flag 09SXtrail
Posted: Oct 8, 2021 at 18:40 Quote
Man, I looked into making my own battery but just didn't feel like I could effectively make it work. My electronics tooling is pretty minimal, as is my knowledge of soldering. I've done some small packs in the past for LED strips in Halloween costumes but nothing that would need to take the same level of abuse.

I'd never heard of Stealth but I am liking what they have going on. For a full suspension mountain bike that sees trail time it seems like the perfect solution. That Pro gen 2 seems like a monster. No doubt the stealth would be plenty.

I did a test ride yesterday on my build and hit 37mph at max assist level. I usually never use the max setting and keep it around the 3-5 range (out of 9). I think if I do another build I may try my hand at a Chinese carbon frame with a Bafang M620 (Cheeb it up).
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