DIY 50km/h Electric Bike Using 1000W Mid Drive Kit
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- Опубликовано: 27 май 2024
- ✅ Bafang BBS02B Mid drive kit (48V 750W) - bit.ly/3PcrQbT / geni.us/VQFF2
👉 Battery mounts (custom made) - bit.ly/4530Fa3
✅ Creality 3D printer - geni.us/IuLA579
In this video I am converting a full suspension mountain bike into a powerful E-bike with a large 967Wh battery combined with the Bafang BBS02 mid drive motor kit, capable of just over 1000W of peak power, 120Nm of torque and up to 100km (62 miles) of range. Great fun, high speeds of over 50km/h (31mph) and reliable parts by Bafang. The battery is mounted to the frame without drilling - using 3D printed supports that hold the battery in place after more than 200km with no issues.
✅ 18650 cells (84 pcs) - bit.ly/49Hi49W
Cheaper, lower quality alternatives :
► bit.ly/3TnWxxd
► bit.ly/3V5fHZW
► bit.ly/3V2um8h
► bit.ly/4c1XYbV
Assembled battery pack (52V):
► geni.us/QWUCl
► bit.ly/3v0rePD
► bit.ly/3Z64pEb
► bit.ly/3v2F7Ng
► bit.ly/3IwUrog
Parts (AliExpress / Amzn):
Battery case (52V) - bit.ly/3Ir7gR7 / geni.us/AfzVa
14S Li-Ion Smart BMS (40A) - bit.ly/3V7EDzR / geni.us/FADU2
58.8V 3A charger (GX16) - bit.ly/3V8JwZE / geni.us/d4z52
18650 Insulation rings - bit.ly/3TnIhEG / geni.us/rUjb
Pure nickel strip (10m 0.1X8mm) - bit.ly/3Yfq24A / geni.us/eGhsS2
Kapton tape - bit.ly/3VOhzUj / geni.us/VOVm
Double sided tape - bit.ly/3USGyVk / geni.us/rHuB9C
Thermal conductive glue - bit.ly/3hbSUKD / geni.us/H4TpXBv
Silicone cable (12AWG) - bit.ly/3FDNL7p / geni.us/FwGA
GX16 charging port - bit.ly/3iTxPVF / geni.us/TxAjoe
XT90 connector - bit.ly/3V7FOPN / geni.us/kCeL
JST connector - bit.ly/3VNOWXz / geni.us/BVDujrc
M5 T-nuts - bit.ly/3Hrayo3 / geni.us/UAIjGxz
M5 12mm bolts - bit.ly/3WcfK3z / geni.us/WBflBf
LED headlight - bit.ly/3FRFD3r / geni.us/PCxfGQ
LED brake light - bit.ly/3heUriZ / geni.us/1DAK1T5
Hydraulic brakes - ebay.us/wdhCwz / geni.us/rTaYuqw
Gear shift sensor - bit.ly/4c3JB6X / geni.us/Y4VuOmA
Programming cable - bit.ly/4a04oq1 / geni.us/Uczl
203mm brake disc - bit.ly/3VMcZpD / geni.us/lcuFc
Disc brake adapters - bit.ly/3uGTdjC / geni.us/AjAKGwG
Handlebars - bit.ly/49J6jQg / geni.us/ltlS
Kickstand - bit.ly/3Br9i0r / geni.us/B0Lff
Grips - bit.ly/3FkB3ca / geni.us/FUMO9
Cable wrap - bit.ly/3C8bHxD / geni.us/CxYqocL
Cable strap - bit.ly/3W6Qj3d / geni.us/ZSdPF
Tools:
TS101 soldering iron - bit.ly/3HUzrI9 / geni.us/owyDm5G
Spot welder - bit.ly/4c3dlAW / geni.us/AKJpvo
Multimeter - bit.ly/3vS2aKG / geni.us/UmrhyYk
Wire stripper - bit.ly/4dG6Jt2 / geni.us/6ep
Bike repair tools - bit.ly/4a4jIC4 / geni.us/80zf
Step drill bits - bit.ly/3Pe3fU6 / geni.us/xYRx7J
Heat gun - bit.ly/3SyxaYX / geni.us/spT5M
Bike repair stand - bit.ly/3v1ftZ8 / geni.us/LzOB11
Socket tool set - bit.ly/3IqOFEL / geni.us/peCCa
Cordless drill - bit.ly/4bZg5PN / geni.us/A5AZi
Helping hand - bit.ly/3B9mIgt / geni.us/Yyqyte
0:00 Intro
0:39 Battery build
17:34 Bike disassembly
20:36 Fork service
27:43 Mid drive kit
28:51 3D printer
33:57 Battery mount
36:41 Assembling the parts
51:50 Finished e-bike
52:21 Test ride 
Наука
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in my opinion this video is one of the best I have seen. The battery build was very clear and straight forward. I built a ebike last year out of my 2014 Devinci with 29 in wheels . A jack model, I put high end commuter tires and a 1000 watt bafang with a48 volt 17.5 ah battery. It bench tested at 99.3 km/h and road tested at my max. so far at 74.3 km/h. that was flat out as hard as i could petal for about two min. lol. 46 tooth on the front. I have about 1300 km on it so far, gone through a chain , two tires, a cassette, and a set of brakes, yes I have pounded this this , but very pleased with the bafang kit. I am craving more power as become more accustomed to the bike . I rarely drive anymore and very inspired by my fellow ebike do it yourselfers. Thanks for your lesson on how to build a battery, I learned alot.
Wow, thank you so much! Truly means a lot to me. Will have to try the BBSHD myself, hopefully this summer. Were you able to pedal at all above 50 km/h? 74 km/h top speed sounds scary haha. The Bafang really is a nice kit to use.
Yes, I am able to pedal at,around, and over 50 km. As one can imagine, you have to be careful in traffic of course, it's the other you got to watch lol. But because I live a little ways out of town I'm able to get onto secondary roads with less traffic and higher speed limits, and that's where this thousand-watt really shines
No words, yet so clear! Congratulations for a job well done!
Thank you! Kindly appreciated.
@@DonnyTerek quanto é
Wow, proper battery mounting solution as that is always the weakest link when mounting a big battery to a tubular aluminium frame. Very nicely engineered, respect.
Thank you! Didn't want to drill this nice looking bike so these mounts work really well to hold the battery in place.
Man, thats a lot. Now I have a greater appreciation for their expense. And, that's just the assembly aspect, now think about all the manufacturing - from the mines to the smelters and, whew! Fantastic, fantastic video.
Thank you kindly! Mean a lot to me.
Absolutely brilliant job, best video showcasing how to do a good job I've seen in a very long while, I will most definitely be recommending your RUclips site to as many people as possible, thank you for a great 54 minutes of something actually worth watching. ❤
Beautiful build! First class work all the way through.
Thank you! Much appreciated.
Perfect build ...thats the level of ebike building i aspire to get to
Thank you!
Excellent combination of bike, mechanical and electrical skills.
Thank you!
purer Genuss dein Video 🤩😍
Ich fahre seit 4 Jahren mit 2,7kWh-14Kg DIY 14s11p Akku 21700er hinten drauf und jährlich 13.000km 😅 aber Front Directdrive Motor und neuerdings Sinuswelle Controller ...ein absoluter Traum diese komplette Ruhe aber trotzdem Drehmoment ohne Ende ☺
I can't believe I've watched 54 minutes RUclips video
Simply amazing 👍😃
Thank you so much! Glad you enjoyed.
Wow that was amazing.. alot of knowledge needed to build a battery from start to finish
Thank you so much!
You are a genius in presentation and engineering skills. Thanks a lot for your work.
Thank you kindly!
That is the ultimate 2 wheel transport. Cheapest to run. Easy to maintain and will go everywhere that a car or pedestrian can go.
A great machine! Even if your battery runs out of juice, you are still left with the ultimate ride--the Shimano pedal transmission, which needs absolutely no electricity and no gasoline to bring the rider home.
It really is! I definitely agree.
Awesome video on battery building. Thanks
Outstanding video! Great camera positioning & lighting & very high build quality! Many thanks!
Thank you so much! Kindly appreciated.
It’s so complicated,only GENIUS like you who can do what you did..
It is actually not complicated at all if you don't build the battery yourself.
Amazing engineering and great craftsmanship.
Thank you! Much appreciated.
Great video, you give me another reason to transform my cheab bike in an e-bike; a big hug from Rome(Italy) in this hot day of sunday!
Thank you so much! Glad to see I may have inspired you!
Flawless! You are so talented.
Thank you! Much appreciated.
Well done mate. Very thorough job on that spot welding.
Thank you! Kindly appreciated.
Nice! Clean installation and custom build.
Much appreciated, thanks!
ЭТО ШЕДЕВР !!! +++ КУЛЬТУРА ПРОИЗВОДСТВА ! СМОТРЕЛ НА ОДНОМ ДЫХАНИИ , НЕ ОТОРВАТЬСЯ!
Great build... And it's quiet like an e-bike SHOULD BE...👍🤪
Thanks!
Это лучшее видео на ютуб, которое я видел... Никому я еще этого не писал. Спасибо! Просто снимаю шляпу.🙏
Man you sure do good work. So eat. Such clean sokders and stuff. My compliments, and I am a very critical guy!
Not very critical of grammar 👍🤣😉 sorry couldn't help myself
@@jordancoleman2402 HaHaHa, thinking the same thing dude! (prob just typo's on a cell phone)
Thank you so much! Means a lot to me.
Very nice engineering... Congrats! As a motorcyclist, I would not recommend positioning the lights side by side as this creates an illusion of being far-away-car to oncoming traffic . Question: I noticed the 6x14 array battery has independent cable routings (balance wires) giving you 3.57V to 50.0V : How does that work? I would assume that this is designed for battery quality correction (?) Is this working with the controller or the charger? Thanks!
It works with the BMS. The BMS has to know the voltage of each group of parallel cells so it can keep the cell groups relatively in balance during final charging. As an option, you can have an additional separate balance unit that balances faster but still needs the BMS unit for over and under voltage cut out, over temperature etc. One bad or weak cell group will be detected by the BMS and will shut down the whole battery even if the overall battery voltage is acceptable.
Thank you kindly! Since I don't use this e-bike on roads with traffic, I keep these lights pointed quite low to light the road close to me. But I agree that it may look like a car approaching. Yes, the battery has 14 independent cables from each group of cells to monitor the voltage and balance the voltage of the batteries. The BMS (battery management system) board takes care of that, which sits on top of the battery.
VERY CLEAN INSTALLATION! KUDOS!
Kindly appreciated, thanks!
Damn you really have a lot of patience to round up all those batteries. Up voted for the effort.
Thanks!
Great video thanks I'm looking at making my own battery this is essential viewing 👍
Thank you! Much appreciated.
Amazing! Well Done!
I recently ordered a 2k watt front wheel 26inch kit for 300$ and a 13a.h 52 volt battery for another 300$. I put em on a 200$ bmx huffy and it would hit 35mph easily and had plenty range. It made me realize just how accessible transportation has really become now. Before
p.e.vs u either rode the bus or has a car or were screwed
2k front wheel, uhm.
@@Stuff-i-Like yup a 2000 watt front wheel motor. Cause they are 100 110 mm and I was using a bmx frame which is 110 in the back
Muito trabalho para montar uma bike dessas , apesar de ter ficado muito top.....parabéns ao biker !!
Congratulations for a job well done!
Great video thanks I'm looking to make my own battery, this is a must, the bike is beautifully done.👍
Thank you so much!
Very professional build ❤
Thank you!
Cool. I made quite the same setup, but printed custom box for batteries and controllers and used ready batteries setup.
Awesome! Would love to see your setup.
That's a nice build. I'm putting together a 750 watt 52v mid-drive ebike kit on my gravel bike right now. ( July 2023 )
Thank you! Would love to see the finished result of your project.
Am impressed!
Great job! Are you considering larger rotors and perhaps 4 piston calipers just for more pressure on the brakes?
Edit...watched to the end and so you did😁
Thank you! Yup, unless I find a reason to put 6 piston brakes 😂
I watched the complette video. Great Work & Video. U inspired me. Greetings from Berlin ✌🏽 have a great day.
Thank you so much! Means a lot to me. Greetings kindly accepted.
Those 3D printed things for stabilising the battery is a great idea. I run a much smaller (36V 16Ah) battery, and after my bike fell over, it now sits in a strange angle...
Thank you! And these mounts do work very well so far. The bike hasn't fallen over yet but after riding more than 300 km over different roads and terrain, it holds just fine without any movement.
Thank You
Very good and complete work.
Kindly appreciated.
Wonderful work.
Thank you!
ABSOLUTELY AWESOME VIDEO!!!!!!!!!!!
Thanks!
Nice motorbike. I'd like something like this for my commute if they were legal in the UK.
Very cool setup! Why all of the redundant battery jumpers? The first one makes a full connection between the lateral straps. Maybe 2 or three for connection security?
Good job that sht has more cables than my motorcycle 😂 very clean build mate
Thanks! 😄
I estimate this bike completed more than 7000+ USD ! Congrats !
You Sir are a BAD ASS. Thank you
Thanks!
Well done!
Master work 👍🏼💪🏼💯
I love the way you created the fixing gadget of your battery holder thru 3D printing, hahaha truly amazing of creating tools nowadays. But i'm still sides of doing things thru conventional way though it may takes a long time.😂😂😂. You are an excellent bike mechanic, Nice Bike DIY works bro.
Haha, thanks! Still holding the battery to this day!
@@DonnyTerek great bro.
Impressive to say the least
Hi thanks for sharing this great build. 😃..Would it be possible to do a short video on the programming part please ? Cheers 👍👍👍
Hi, thanks for watching! The programming may sound and look difficult but it is very straightforward. There is plenty of info online, I used the very first link that popped on search: electricbike-blog.com/2015/06/26/a-hackers-guide-to-programming-the-bbs02/
Yeah well this guys is clearly a professional at assembling that battery.
Haha, thanks! Not my first build but I wouldn't call myself a professional yet.
Amazing work
Thanks!
awesome project and great video. interesting to know and maybe is something I could do on my bike.
Thank you!
GOOOOD JOB !!!
Thank you!
Besides the battery we can learn how to do the suspension maintenance and other great stuff.
Hi do you have any problem with engine bending rear wheel to the right side? I have very similar frame in my bike and i want to instal bbshd but i am a little be worried about torque destroing my rear frame and suspenion. What do you think about it?
Awesome clean job start to finish. You should be a trainer at Tesla.
Haha, thank you!
I was gonna say now add your 3 in one oil!... But will it ride like a Catalac?... Really fun to watch!...
A clean build as usual. But pay attention driving those twin LED lights directly from the Light output of the Bafang BBS. While those LEDs are usually wired in series and run fine directly connected to 6V, the light output of the BBS only has very limited current like 500-750 mA AFAIK. I am using a MOSFET as switch when powering higher current lights.
Yes 500mA is correct
Thank you kindly! Yes, I am definitely aware that the light output cannot reach over 500mA. I actually soldered a 1.5 Ohm resistor inline with the 6V output to limit the current to around 450mA. At first I thought it would be too dim at only 2.7W but it is actually quite bright.
@@DonnyTerekçok kaliteli bir işcilik
tebrik ediyorum.
@@recepyosunkaya2155 Thank you.
Nice awesome concept bike battery power pack yep
Fantastic bike!
Couple of questions:
1) You began with a "Mountain Bike". Would this work starting from a "Hybrid-style" bike? (This seems to be a Bottom-Bracket fit question)
2) Was that a 10 speed rear cog you installed? What kind of rear-hub spacing is required for that?
3) This is the _second_ mid-drive ebike conversion video I've seen that goes into great detail about the Speed Sensor, but _totally_ ignores the SHIFT sensor! Please explain.
4) What does the entire bike cost?
5) Why did you re-build the front fork?
6) I noticed you did not show balancing the batteries. Is this un-necessary for an e-bike?
Reply appreciated.
Probably work better with a hybrid, due to the spacing around the bottom bracket area.
You need a suitable freehub - need to put a wide range cassette on, as you lose all but one chain ring.
Not everyone uses a shift sensor. Some people can ride a bike and back off for shifting, or jab the brake insead.
The bike looks ancient, with lots of cheap Chinese crap on it, to try and update it. Shop around, prices variry wildly from place to place - try PSWpower
It say in the vid - fork service - you are supposed to do that occasionally.
The cells would be balanced before assembling into a battery, and it's very long and boring (but not as bad as the battery welding)
Tu vídeo me inspiró lo voy a intentar gracias
Amazing Best video master Man👍
Thank you!
I half expected you to construct each 18650 cell.
that's so clean
Thanks!
I had such bike for 2 months and sold it, it is a beast a daemon that eats your bike driving system if it has any aluminium part, yes it can climb any mountain it is fast but for long term usage especially like in my case driving mainly in city it is an overkill and way to heavy
Thanks for sharing this impressive build video. The video and the bike are very nicely done. I was curious if the hydraulic brakes function well in the cold weather?
Yes
Hey, sorry for the late reply and thank you for the comment. No issues for the brakes.
Thanks, respect!!
Thank you!
Respect!
AMAZING!!!!!!
Amazing, you sir remind me of Dexter, Dexter of bikes...
Haha, thank you!
Wao great , looks pretty👍 enough
Thanks!
@37:09 Did you put the thermal paste into the Vastfire lights?
The similar Solarstorm X2 comes without paste, bad for heat dissipation...
Awesome Awesome Awesome Awesome Awesome
Nice job.👍
Thanks!
I wish i could make complete DIY E-bike (LONG RANGE WITH DURABLE BATTERIES) like urs to travel whole world ! Its my dream n after watching ur video all those step by step detail guide i think i can also make one to fulfil my dream ! Thanks buddy 😊 ! PLZ KEEP ON uploading new videos to double up range 🙏 so that we can learn more from u . Stay blessed n stay HAPPY 😊 ❤
Thank you! Hope you will consider subscribing so you don't miss out!
awesome work , my lenkeleisi 400 watt unlock run just hit 42km/h
Thanks!
WOW!..Could you do a parts list for the bike and electric conversion kit please...pretty please?
Done! Please check the links in the description.
@@DonnyTerek Thank you!
Wow!! GJ!!!
😄👐
Impressive 👍
Thanks!
Congratulations, nice job! Does the BMS disable charging in case of a bad battery or battery cell? If one of the battery cells breaks down while cycling, is it not possible to continue using the bicycle or only with lower performance?
Thank you! As much as I know the BMS does not disable charging if one cell goes bad. You can continue using the bicycle (which is not recommended) but the battery capacity will be lower by one cell's.
Years ago nobody told ot wrote about the max rider weight...today we are all concerned about it...and the positive thing is that you can upgrade the motor or the battery as you want not so with the normal e-bikes.😊
all is done professionally, but still every now and then ptsd triggers for me, i remember doing packs, and how spontaneous combustion and sparks can happen if something is shorted, be extremely careful when dealing with cells. Even slightest short can be catastrophic, it is like trying to disarm a bomb each time. Notice how extra precautions are done with tape to prevent short.
Very great method shown sir and how to make sweet pack with full detail I got a chance to learn a lot you set up setup in BMSK you have given me a lot of knowledge thanks sir
Electrical engineer here, please dont ride this bike hard. The battery series connections are not sufficient for what you are doing, the parallel connections are fine however the series connections will be taking the full 1000w/48v~=21A.
Doing very rough calculations as there are many unknown variables.
A = .1mm×8mm=.8*10^-6
Pure nickels resistance at room temp is 6.99*10^-8[ohm]*m approximating to 7 as it will be warmer
R=(7*10^-8)/(.8*10^-6)=8.75*10^-2
Assuming heat transfer coeff. Is 2w/m^2K which is an average in poorly ventilated areas which is your case.
p=2*(8mm+.1mm)=.0162m
P=2W*.0162m*60C=1.944W/m (taking 60c as thats the temperature when some things can go into thermal runaway.
I=sqrt(1.944/(8.75*10^-2)) ~ 4.7A*5S connections =23.5A
My calculations are rough and approximate not taking into account the heat and resistance from the batteries which will significantly contribute, and not taking into account the changing resistance as the nickel heats up.I would highly suggest upgrading your series connections with another layer or two of nickel strips as it does have a risk of fire if you ride it at the full 1000w for extended periods.
No way... you did the exact same thing I did back in 2020 when I installed a BBSHD. I cut and installed a JST connector on the Headlight wire just like that. GMTA. Mostly because I use a GoPro mount for my headlight and I wanted a simple way to disconnect it up by the head light.
🙂 👌One of the best DIY movies ever seen on YT ,, Thank You very Much ,, >> Keep It Up & Take Care...👍🍀
Much appreciated, thanks!
Go on bro, This is well put together, I got a BBS02, I proper enjoyed putting the motor on my Carrera hellcat lmt edition, lol, I put Zoom hydraulic brakes on it though, The wire brakes are terrible for a Bafang Motor, The hydraulic brakes makes the bike so much better, Safer, lol, I was going to do a battery myself, But after reading about all the fires it put me off it, I am glad though as I live in a block of flats and it not right to risk doing something wrong, I couldn't live with myself lets just say, So I bought one of the Triangle batteries off Amazon, It is actually worth the money as it goes for long time, lol, I still have not run the thing down, Is it better to let the battery go all the way down so to speak, I haven't let the battery go past 50% I think, I haven't had it long though, Great battery I will say the triangle ones, I want to do another E-bike, An enduro it is just money at the moment, Everything is way too expensive here in the UK at the moment, I will do another one one day though, I have had the BBS02 for 2 years now, The Bafang is by far the best DIY motor anyways.....
This is a top build bro....
Happy riding.............
Peace......
Thank you so much bro! Happy riding to you as well!
I love the way you presented how to assemble the battery but got lost near the end in how you connect the wires for the charger and the power.
Thank you, it may seem difficult with all the wires dangling around but it is rather simple if you look up 'BMS wiring'.
Hello yt algorithm see u with 5 million views 🙃
🤞
An excellent bike build with a lot of thought put into this build, the only thing that confused "me" was the battery build, the most confusing is the BMS. Any chance of a video on how to build a battery? step by step I would love to see one from you? Once again this was Excellent.👍👍👍👍👍
Thank you so much! I can definitely see why the battery build might seem so confusing. There are simply so many tutorials and info online on building batteries that you can learn from, so I guess my tutorial wouldn't help more. I recommend you read and watch more RUclips about BMS wiring to understand it's basic functions and wiring. From there it won't be too difficult to understand the battery wiring itself. Hope this was of any help, best of luck and thank you once more!
Just saw you put the black bms wire to the battery negative , I thought the blue wire was to the battery negative and black was out put to load . So how did this work out for you ? Always wondered just what would happen if they were reversed .
Nice!!
Thanks!
This is impressive and inspiring! nice work!
Question for you, my shift cables run under the bottom bracket of my bike, the mid drive motor will certainly pinch these cables, how do people get around this usually? Thanks!
Thank you!
Which cables run under your bottom bracket to be precise? Front and rear derailleur cables or only the front?
No thank you brother, it inspired me.
The cables for front and rear derailleur run under the bottom bracket. The front derailleur will be gone. I saw in another video, that they just added a rubber spacer between frame and motor so that the rear derailleur cable can run in between the frame and motor
@@Voltermort That's what I thought, a rubber spacer should help. Or re-routing the cables if possible.
@@DonnyTerek appreciate it. Rubber spacer sounds much easier
How did you keep the Printed Battery Brackets square using zip ties?...
he used double sided tape to lock them in place and the zip tie was for the pressure but i doubt the plastic would be durable i would've used metal zip ties
Hi im a newbie, i just ordered 1000w bafang with 19,2 ah battery, i didnt order a bms board, is that to prevent engine to overheat or whats the point? and disadvantages of not using it? Thanks
Hi, sorry for the late reply. You should be all set, since pre-built batteries will have a BMS board installed to monitor the battery voltage.