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DIY ebike: 1kW Fat Tire AWD snow bike for $700 + 4 hours of work

DIY ebike: 1kW Fat Tire AWD snow bike for $700 + 4 hours of work 2020-10-01Leave a comment

fats tire electrical bike DIY ebike: 1kW Fats Tire AWD snow bike for $700 + 4 hours of labor

Winter is coming quick right here within the Northeast and my ebike espresso store commute goes to be unimaginable quickly with my daily ebike. I used to be intrigued by a post in May by Micah which touted a fat tire ebike for $700. I made a decision to begin there and tailor the construct to winter wants whereas nonetheless conserving it at round $700. What I wound up with is a ton of enjoyable…

I ought to notice on the outset that Mongoose contacted us after the unique story ran and advised us that their Dolomite bike hadn’t been examined as an electrical donor bike. Nevertheless, performing some analysis on the ol’ web confirmed {that a} ton of individuals had used a Dolomite with success resulting from its sturdy metal design and particularly sturdy entrance fork. Simply in case nonetheless, I opted so as to add not one however two torque arms to the entrance of this construct and improve the disc brake to one thing extra substantial. Proceed at your individual danger.

Substances:

So right here’s the construct you see earlier than you:

Elective however extremely advised:

  • Torque arms (pack of two): $16.50
  • 160mm Front Disc Brake: $13 – not solely improves braking on the heavier, motorized entrance wheel but in addition doesn’t require you to elevate the disc off of your donor tire

All the components got here inside per week, whereas the Amazon battery being prime shipped in two days. I first put the Mongoose Dolomite bike collectively which takes about 15-Half-hour relying in your ability degree and instruments. I placed on the entrance wheel and rode it round to verify I had donor bike to begin with.

It is a 48-pound heavy, metal fats tire bike with fundamental parts together with 7-speed rear derailleur with proper aspect grip shift, disc brakes and 18-inch body. I initially anticipated Huffy/large field high quality however that is positively a step up.

The large fats tires make up for the shortage of suspension and taking this off-road is a thrill even with out an electrical motor.

DIY ebike

Fats Tire DIY ebike, However Why?

I at present ride a 2017 Raleigh Redux IE 5 miles to work within the morning however I don’t really feel protected with it on slick or snowy roads that embrace steep inclines and blind turns. Reality be advised I most likely gained’t trip to the espresso store most days throughout the winter however I would love an choice if I’ve the time and inclination (and waterproof apparel). I’d additionally like a motorcycle for family and friends to come back with me after I trip my Sondors X by means of the woods or on trails.

Listed here are a few of the choices that mapped out my selections.

Value

I wished to maintain the worth as little as doable since this can be a particular use bike.  Rear wheel drive Sondors X fats tire 500W prices about $1200 for the same configuration with a pleasant $100 show and $100 entrance shocks.

As for the motor, I wished one thing substantial. It is a heavy, inefficient bike to begin with, so a 250W and even 500W motor wouldn’t have made this enjoyable. A 48V 1kW hub motor continues to be very cheap with full non-battery kits (together with throttle, controller, fats wheel and extra) costing beneath $200.

DIY ebike

Entrance Wheel Drive/AWD

Since this bike is for snow and I have already got a RWD fats tire Sondors X, I wished to attempt a entrance mounted hub motor. Since I’m nonetheless pedalling the again wheel, it turns into an “all wheel drive bike” which ought to assist in snow. Anecdotally, I’ve heard that entrance wheel acceleration and further weight helps by means of turns in snow however I’ll have to attend for the white stuff to check that out. Additionally the entrance wheel is quite a bit easier to improve and since that is my first full construct, I’m aiming for simplicity.

Different concerns: I would like my 11-year-old son to have the ability to use this, so conserving it easy with a smaller body is smart.

Electrifying Mongoose Dolomite

These directions will assume you’ve fundamental bike and mechanical/electrical DIY expertise. You’ll must have a hex package, screwdrivers and different fundamental instruments.

Entrance Wheel:

  1. Flip the bike the wrong way up and take away the entrance wheel by unscrewing the nuts on the perimeters.
  2. Deflate the tire and take away the tire and tube and put them on the black/silver motorized wheel.
  3. Add the brake disc to the motorized wheel by eradicating 6 hex nuts. Tighten hex nuts again up.
  4. Put the wheel onto the fork ensuring that the disc goes into the brake pads easily. The lead energy wire needs to be on the best aspect of the bike (when proper aspect up).
  5. Fasten torque arms to the fork of the bike with included clamps. Screw the included bolts again on.

Controller:

  1. I mounted the admittedly generic controller on the downtube reverse the place the battery is. I’m fairly positive this isn’t the most effective place to place it, however after attempting/failing to place it within the triangle and proper above the kickstand, this gave the impression to be the most effective place for wiring.
  2. DIY ebike
  3. Merely mark and drill 2 small holes within the down tube and screw it in. In case you are helpful, use a rivet nut tool to place in some rivets. It is a $700 construct so I simply screwed them in with some washers. We’ll join the wiring later however outgoing wires needs to be pointed downward towards sprocket/chain which will even assist to maintain them dry.

Battery:

  1. Flip the bike onto its wheels and put down the kickstand.
  2. Slip battery out of its holster – you’ll want the included key.
  3. You’ll use one of many water bottle holes and a gap you’ll have to drill larger as much as affix the battery to the body. You may even need to drill a 3rd gap (I solely did two and appear to be effective up to now). Use washers nonetheless to distribute the drive over a wider space or these screws may break off.
  4. To unravel the holster, you’ll must unscrew 3 screws that can reveal a metallic screw gap.
  5. Be sure that the holster is tight and LEAVE THE BATTERY OFF for now.

DIY ebike

Wiring:

  1. The toughest a part of wiring is placing the battery cable beneath the crank and conserving it tight. You’ll then must affix it to the massive pink and black wires popping out of the controller. Ensure you don’t have energy coming down these wires both by utilizing a multimeter or simply ensuring the battery isn’t related. I soldered the wires and lined them with electrical tape, however you would simply use butt connectors.
  2. Subsequent, run the motor wire over to the fork and down the best aspect to the motor interface. Be sure that the pins are lined up and plug it in. At this level you’ll be able to plug the battery in and take a look at the motor with the throttle. You must get energy to the wheel.
  3. Run the throttle and the brake as much as the left aspect of the handlebars. You’ll need to pull the Mongoose grip and brake and exchange it with the left aspect brake. Notice, you’ll be mounting the throttle the wrong way up on the left aspect because you’ll need to hold the grip shift on the best. I do know this isn’t optimum, however belief me it really works out nicely.
  4. I personally didn’t connect the best aspect brake cutoff or the cadence sensor as a result of I would like full management of the ability output and there are not any “modes” on this throttle/controller.
  5. You’ll need to tie down the entire wiring utilizing twist ties and/or extra optimally some clipping. I’ve some future plans so the bike you see nonetheless has a number of work to do on this space.

DIY ebike

Executed!

How does it trip?

General, it’s a ton of enjoyable. In testing I obtained it up close to 30mph on flat floor pretty simply. At that velocity nonetheless, the entrance wheel’s imperfect steadiness turns right into a rumbling and albeit such a bike is reaching the outer limits of its construct parameters. I really feel comfy nicely over 20mph which is the higher restrict of the Sondors X, in order that’s a win.

The drive practice isn’t good nonetheless. Should you gun it from a cease, the motor typically vibrates in a bizarre approach then shuts off. Nevertheless, you’ll be able to twist the throttle once more and it runs effective. I discover {that a} rolling begin or a easy throttle acceleration fixes this challenge. I’m 6 foot, 230 lbs. and my son at lower than half the burden barely has the difficulty so it may additionally *ahem* be a dimension concern.

After performing some analysis and speaking to Micah, it appears like a greater controller is not going to solely remove this downside however will even permit the motor to function extra effectively than its present 80% and obtain the next high velocity. I can even get regen which can be a profit for me in my hilly environment (and low-end 10Ah battery).

It will even be good if the controller was higher suited to bike mounting relatively than its rectangular form with sharp edges. I’m nonetheless purchasing round for that good controller, however within the meantime my wires are simply taped to the bike and don’t look nice.

Additionally, I’m not in love with the battery placement and in future builds I’m going to attempt both a triangle bag or a rear rack mounted battery. This could even out the distribution of weight somewhat bit and provide a splash guard, storage and rear mild at a couple of $100 value premium. Because it stands, I don’t know if I belief the screws within the tube to carry the 4.4Kg/9.68lb battery pack over tough terrain.

The bike weight is somewhat over 70 lbs. all collectively which isn’t insane. It’s simple to maneuver and never onerous to throw at the back of the automotive or on a sturdy bike rack. I can get about 10 miles of principally full throttle 20+mph vary on flat-ish roads. Extra with pedal help and slower speeds clearly. It takes about three hours to completely cost.

Conclusion

I like this factor and am blissful to point out it off to locals. It has up to now been dependable and a enjoyable crowd pleaser over the primary 50 or so miles. I’ve taken it on retailer runs and to dinner events with out a problem.

Though Mongoose doesn’t endorse this and in reality warns in opposition to it, it looks as if a construct {that a} large field retailer or an organization that makes cheap bikes (like Mongoose!) ought to embrace. I think about if this was constructed as a complete package deal on an meeting line and could possibly be bought in enormous numbers at scale, the whole constructed value might get down round $500 and turn into much more lovely and dependable. And at that value, we might take a complete lot of larger ICE autos (soiled scooters, bikes and a few automobiles) off the road.

In fact, I’m not totally happy with 30mph/48kph so I’m now a 3kW/72V build for spring…or I might just get a Sur Ron like Fred. What do you suppose? Let me know within the feedback under.

DIY ebike

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