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Gravity BullseyeMonster LTD with BBHSD and 52V 13.5 ah Panasonic Shark Pack

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  • Gravity BullseyeMonster LTD with BBHSD and 52V 13.5 ah Panasonic Shark Pack

    I started reading about eBikes over Christmas vacation last year and was bitten by the must build it now bug. Between electribke.com and electricbike-blog.com I found all the information I needed. The bike needed to be phat (thanks to electricbike-blog.com...formerly exclusively about electrified phatties) and it needed a mid-drive since I wanted to take it on trails and commute. My main motivator was a head injury a few years ago that prevents me from bicycling like I used to.

    The bicycle: Gravity BullseyeMonster LTD from BikesDirect.com -- $599
    I started with the Gravity BullseyeMonster LTD. I know it cost a little more than the BullseyeMonster, but I liked the wider tires, tapered head tube and of course the color. The mega bonus with some terrific father-daughter time while we put the bicycle together. I liked riding the bicycle around so much that I held off on buying the motor and battery and doing the build for a while so I could tool around on it.

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    The motor: Bafang BBSHD 1000W from Lunacycle.com -- $669
    After reading many many blog articles, I settled on the BBSHD. I wanted the extra power for trail riding and the motor is newer than the BBS02 so I thought it would likely be around for a while. I bought the 120mm width version because the BullseyeMonster LTD has a 100mm bottom bracket. The toughest part about making the install work was getting the old bottom bracket out and using a rotary tool to smooth out the inside of the bottom bracket as some of the frame parts stuck into it a little. I also dabbed a bit of grease in there to get it to slide in easily.


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    The tools: bottom bracket removal tool, chain breaker, Luna wrench -- $20/each
    I searched for the bottom bracket removal tool all over town and found it at the eighth bicycle shop I stopped at. Later I need a chain breaker and had to run all over town for that as well. It wasn’t until after I’d been to lots of bicycle shops that I realized REI had everything I needed and was a LOT happier to sell me the tools to do the work than the local bike shops were.

    I get that they’re just trying to make a living working on bikes, but the whole point of this experience for me was to build it (or break it) myself and ultimately I’d rather buy the tool and learn in a situation like this than pay someone to do it. If you have a local REI, go there, otherwise, save yourself the hassle and order online or…as many have suggest, let the local bike shop do it for you.


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    Do yourself a favor and buy the right tools and have them on hand before you start, otherwise you’ll end up sucking wind like I was waiting for parts to show up.

    I managed to avoid buying the crank removal tool, but will likely end up buying one anyway. I’d like to go back and loctite a couple more bolts that one of the cranks currently blocks. I found the tool locally for around $25…less if you buy it online.


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    I used the chain breaker to splice in an extra section of chain to get the proper length so I could use the gears on the bike. I don’t need them much for commuting, but they’re a huge help on hills.

    The Luna wrench is a must have for tightening up the bits that hold the motor on the bottom bracket. Last time I checked the BBSHD kit, they actually had it listed as an optional tool you can buy--check the box and get it when you get the kit.


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    The battery: Lunacycles Shark Panasonic 52V Shark Pack -- $475.95
    This is where I may have messed up. I bought the 13.5 AH long-range NCRB batteries. These are supposed to be good for distance. I’ve only put about 40 miles or so on the bike so far and the range was in the neighborhood of 25 miles from full charge (I bought the advanced Lunacycles charger -- $100). Most of that was a commute to work…all downhill from my house, all uphill from work. I used quite a lot of pedal assist headed home and the battery meter on the display showed the battery to be a bit under half when I got home…though the final push up the last half mile had it temporarily down to two bars. I took the bike out for a quick ‘round the 4 mile block and pushed it hard trying to kill the battery and succeeded just as I was getting back to my house. Happily it died predictably, not suddenly and after letting it rest a bit, I was able to fire it back up and motor the rest of the way home (with pedal assist).


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    The reason I say that I may have messed up is that I believe the GA cells would’ve been a better fit for what I want to do. I haven’t had the bike on the trails yet, but after seeing how much power the motor seems to draw going up hill, I believe my range will be significantly diminished once I start riding off-road.

    One thing to note--my battery came in a fairly busted up box, but packing inside seemed to be good enough to protect it. Love the unheeded warnings on the outside of the box.


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    The rest: chain -- $10 from REI, master links --$4 each from REI, XT90S Connectors with pigtails from Lunacycles $6/ea., Luna Eclipse chainring -- $100 from Lunacycles, Spacer kit -- $10 from Lunacycles, Bolts -- $5 from Ace Hardware
    I needed a few more things as the chainline was way off when I began assembling everything. I wanted to use the Luna 42t sprocket I received as a free upgrade, but the chain just wouldn’t stay on. After some research it sounded like the Eclipse chainring was the answer, so I ordered that and indeed it does fix the chainline.


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    I bought the XT90s connectors and soldered those onto the battery mount and the motor after a bunch of reading in the 3-part BBSHD how-to guide on the electribike.com site. The connectors (with pigtails) were fairly easy to install and the shark pack setup means you can remove the battery while you’re doing the work…which means the job is a lot safer.


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    The stock chain on the Gravity BullseyeMonster LTD was not long enough, so I spliced in almost half of another chain thanks to the folks at REI. This is not ideal as far as I’m concerned and I intend to go back and install a right-sized chain in the future (assuming there’s one out there). Something I learned here is there’s basically two chain sizes…there’s the chains for single speed bicycles and chains for bicycles with more speeds. The difference is the width of the chain.

    Fitting the BBSHD to the bottom bracket of the bicycle required some finesse as the rear triangle is very wide. I figured out pretty quickly that I needed an extra spacer kit. I didn't get photos of these, but they're the same spacers that come in the kit...I just needed a few more to get things to work.

    The bolts from Ace Hardware were for the mounting plate that must rest against the BB (it loops around it) and then screws into the motor itself. The screws that come with the kit are really long and I’m not sure what they were thinking on those. Luckily Ace had exactly what I needed.

    That’s most of it. Nothing was super hard. There’s lots of info here to keep you pointed in the right direction and in the end I have the satisfaction of knowing I did it all myself.

    I brought the bike to work and did a show and tell. Now I’m the eBike expert in the department. Hopefully I’ll convince more folks to build eBikes. I’ve already been pointing people towards Lunacycle.com.


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    Last edited by motoray; 08-28-2016, 07:07 PM.

  • #2
    Parts List
    Bicycle: Gravity BullseyeMonster LTD Bikesdirect.com $599.00
    Motor: Bafang BBHSD 1000W Lunacycle.com $669.00
    Battery: Luna Panasonic Shark Pack 52V 13.5 ah Lunacycle.com $475.95
    Charger: Luna Advanced Lunacycle.com $100
    Bottom Bracket Removal Tool Local Bike Shop $20
    Chain breaker Local Bike Shop $20
    Luna Wrench for BBSHD Lunacycle.com $19
    Crank Puller Local Bike Shop $25
    Additional Chain REI $10
    Master Clips REI $8
    XT90S connectors (bought 2, need 1) Lunacycle.com $12
    Eclipse Chainring Lunacycle.com $100
    Misc. bolts Ace Hardware $5
    Total $2062.95

    Comment


    • #3
      Thanks for doing such a great job documenting this for future readers. There is definitely some work involved, but once builders get an accurate picture, those with the desire to do so can take the plunge, and then others who so inclined can pay a shop to either remove the crankset, or install the drive, or both. Some of the tools are listed separately (instead of being included) because half of the customers now are on their second ebike (for a family member or friend) and they already have a full tool set from the first ebike build.

      If you get the itch to accesorize a little more a few months from now, I highly recommend a suspension seat-post (either a Thudbuster or Suntour NCX), and a left side mirror. Down the road I will be adding a drink holder and DC/DC converter to power a 12V light set (direct from the ebike battery pack), and also to power a radio.

      Comment


      • #4
        wow, nice work! looks pretty much like a clean perfect install

        Comment


        • #5
          nice build, I did a similar one recently with the Sturgis Bullet from Bikes Direct. Looks like you mounted the battery upside down.

          Comment


          • #6
            Originally posted by dustinst22 View Post
            nice build, I did a similar one recently with the Sturgis Bullet from Bikes Direct. Looks like you mounted the battery upside down.
            I did put the battery in upside down--intentionally for now. Since the battery locks onto the base plate, it's secure enough, but mounted this way it's removable easily. If I flip the plate around it just barely gets in there. Eventually I intend to drill a new hole up higher so I can mount it properly. I was just itching to ride. :)

            Comment


            • #7
              Originally posted by spinningmagnets View Post
              Thanks for doing such a great job documenting this for future readers. There is definitely some work involved, but once builders get an accurate picture, those with the desire to do so can take the plunge, and then others who so inclined can pay a shop to either remove the crankset, or install the drive, or both. Some of the tools are listed separately (instead of being included) because half of the customers now are on their second ebike (for a family member or friend) and they already have a full tool set from the first ebike build.

              If you get the itch to accesorize a little more a few months from now, I highly recommend a suspension seat-post (either a Thudbuster or Suntour NCX), and a left side mirror. Down the road I will be adding a drink holder and DC/DC converter to power a 12V light set (direct from the ebike battery pack), and also to power a radio.
              What do you mean "if I get the itch to accessorize?" Doesn't that come with building one of these. My Christmas list is already a mile long with new bits for the bike. :)

              As for the work involved--the actually assembly of the bike, installation of the kit, etc. probably didn't take longer than eight hours--and that's with me going really slow so the kids could help. Now that I've done it, I'm sure I could put it all together much faster.

              FWIW--anyone in the Bend, Oregon area is welcome to look me up if they're doing a first build--I'd be happy to talk eBikes!

              Comment


              • #8
                Hey Motoray thanks for sharing your build! Did you get the C965 display with your kit? If so, what did the battery meter show when the low voltage cut off occurred? I thought that the C965 did not properly display battery levels with a 52V battery as it is designed for 48V.
                Cheers!
                ian

                Comment


                • #9
                  Hi another question: What was the stock chain ring size? When you say you put on the 42t Eclipse you had to get a longer chain, was that because the original chain did not go on at all or only one the smaller sprockets? Seems like adding another half of a chain is really long.

                  Comment


                  • #10
                    Hi rcbike--I did put on the C965 display (http://lunacycle.com/parts/bafang-pa...-1000-display/) and when the motor cut out, it was showing a flashing (empty) battery bar on the display.

                    The stock chain ring on the bike was in the neighborhood of 31 teeth, so the Luna was quite a bit larger. The original chain would get on the 42t aluminum luna chain ring, but by the time I got the Eclipse, I'd already cut the chain to add in the links. I may yet take a couple of links out though as I suspect the chain is a bit long right now--I figured easier to take links out than add them back in. Shifting mostly works now though--it misses a gear now and then---but then I probably need to adjust the derailleur a bit too--the thing that's stopped me from doing that is with a moto on, I feel like the bike really only needs about 4 gears so I haven't worried about it skipping now and then.

                    Comment


                    • #11
                      Thanks Motoray! That's good to know that the C965 battery level indicator will work with the 52v battery packs. I thought I would have to get a Watt meter or Bat Man to know how much the battery is draining but if it was showing empty bar on the C965 display then then I know not to let it go past 1 or 2 bars.
                      My donor bike has 32t on the chain ring and I'll check to see if will go on the 42t Eclipse but I bought an extra chain just in case I need to add more links.
                      cheers!

                      Comment


                      • #12
                        Thanks for the great post Motoray. I was hoping you would entertain a couple of more questions, but no problem if you don't have answers.

                        1st, I'm wondering why you went with the 100-120mm kit versus the 73-100mm kit? I think I would rather grind a little metal at crank housing instead of adding a bunch of spacers. I can see the advantage of having a little more to play with though.

                        2nd, I'm going to use my bullseye monster (arrives next week) for mainly up hill riding of old logging roads etc. You stated you wish you had gotten the GA battery instead. Do you have any idea of which GA battery you would have purchased? Seems to me like there is a tradeoff between more battery weight and more power, but I'm open to thoughts on this.

                        3rd and probably least important. Would you recommend thumb throttle or twist throttle for the 8 speed bullseye?

                        Thanks in advance for any feedback you have. 4x4magnum.

                        Comment


                        • #13
                          Hey RCBIKE,

                          I've now had the chance to ride the bike a bit more and have the power cut out again. My experience was the same losing power...bike got down to 1/2 bars showing and then I kinda amped it up (pun intended) with a heavy throttle and the power went out completely. Just as before, I was able to turn it back on after 3-5 minutes or so and get some additional assistance--enough to get me home again (good since I was out in the woods). Maybe part of the incompatibility has to do with it not registering that there's still power when you get down low like that. Dunno. On that particular instance though, I started with the battery showing a bit less than 50 v (on the advanced charger) and rode about 10 miles in the dirt/hills--not what that pack is supposed to be good at.

                          For comparison, I charged it up and rode the next day...all street, PAS 1-5 but mostly 1/2 and the battery meter didn't move at all.

                          Comment


                          • sandiegan
                            sandiegan commented
                            Editing a comment
                            motoray, considering you are riding in the trails and gain power back after a 'cool off' period, perhaps the controller is experiencing thermal shutdown? I have the temperature mod on my unit and the hottest I've seen it is towards the end of a session when ripping around in the trails. If you ever service your motor I highly recommend you do the temp mod while you are at it.

                            Bend is an awesome place to ride, by the way. I bet it's a rush out there!

                        • #14
                          Hi 4x4mangum,

                          1. I don't have skillz for grinding, so that was part of my decision. After doing the build, though, I have to say I'm glad I went with the larger kit. The rear triangle is really WIDE to get that phat tire in. Not sure I could've gotten a good chain line on that particular bike without the BB width to move the drive side out a bit (I had to use spacers there to move the chain ring away from the frame. I imagine you could still do that with the 100mm kit, but you'd be doing a lot of grinding I think.

                          2. There's a similar shark pack GA battery--52v, 13.5 ah. That's the one I would've gotten. Having now ridden offroad in silty/sand with lots of up/downhill and then immediately taking the bike out the following day for a similar length road ride, the battery pack I got clearly works better for onroad/commuting. I'm pretty sure it said as much on the page where I ordered it, but I had the mistaken belief I'd commute on the bike more (have to haul kid to school now that school has started, so probably not going to commute anymore--but had some odd experiences there with people not expecting a bicycle in the bike lane to be moving so quickly and pulling out in front of me, etc.). If you read electricbike-blog.com, you'll find a post where he reviews the GA cell for off-road use and highly recommends it. I tried to save a few bucks--and shouldn't have.

                          3. The thumb throttle can work, but for me it interferes with shifting. Less of a big deal on the pavement, but definitely a bigger deal off road. Of course, in most situations where I'd shift, I can just hit the throttle a bit too, and no matter the gear the bike usually just goes. However, I'm a motorcyclist and fully intend to put a the twist throttle on eventually because that's how nature intended throttling to work. Plus it'll be easier for me to shift.

                          Ray

                          Comment


                          • #15
                            Motoray,

                            Firstly thanks for your post.

                            I do have a couple of request if you can.

                            What size frame did you get? How close is that Luna sprocket to the chain stay?

                            And can you post a good picture of the chain-line with the chain on the lowest gear? And post a picture of how close that Luna Sprocket is to the chain stay?

                            Glenn

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