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Enduro E-Bike (BBSHD-Mid Drive) 11Speed Custom Build (No BMS)

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    Enduro E-Bike (BBSHD-Mid Drive) 11Speed Custom Build (No BMS)

    Hi, Just Finished my Enduro E-Bike Frame Build, "Mid Drive" BBSHD with:
    - Shimano 11Speed (M8000 XT) Drivetrain

    - Lekki Bling Ring HD 46T Front Sprocket (Recently changed to a 42T to reduce motor temps & increase Torque for Hill Climbing)

    - Sunrace Rear Cassette 11 - 46T (Great for good top speed & Excellent hill climbing ability

    - 203mm Shimano XTR Icetech Rotors & XT Calipers with Magnetic Cut-off switches fitted

    - Harley Davidson 3 position Ignition switch fitted

    - Solid State Relay for Control Work such as Joining 8S & 7S Batteries in Series, USB, & Led Headlights (100A 80v Dc to Dc Relay) 3S/3P Aux. Battery located at front of Frame for Control Work

    - Rims (Mavic EX 729) with Maxxas Minion 26 x 2.5" Tyres

    - Front Hub (Shimano Zee HB-M640)

    - Rear Free Hub (Shimano ZEE FH-M645 32H) EFHM645D50B .... It's a 12mm axle and 150mm OLD and 32Hole (couldn't get 36Hole Rim at the time of purchase)

    - Rear Shock (Rock Shox Vivid R2C (240 x 76mm)

    - Front Forks (Rock Shox RC 200mm Travel)(Dual Crown) Thanks Luna Cycles

    - 15S / 10P custom made Battery Packs (without BMS) 1x 8S/10p & 1 x 7S/10p (Currently Charging to 4.08V per Cell without issues)

    - Made custom Enclosures with Soviet Miltary Plugs for Cell log 8M portable Voltage Checkers to monitor All Battery Voltages while out on the Trails

    - Modified IP54 German Power outlets (cut out guts of outlet and used flip style Ip54 Black cover faces to house my Charging/Balancing Plugs - 1 x Charging, 1 x Balancing & 1 x Charging & Balancing for the Aux 3S/3P Battery which operates Solid State Relay, USB, & LED Headlights

    - Custom made Battery box to house 2 x 35AH Battery 8S/10P & 7S/10P (Batteries can be easily removed from the side, once bike side panel is removed) (3mm insertion Rubber Lined/Glued throughout Box)

    My biggest ride to date was a 36km Hard & Hilly Terrain Trail, with plenty of battery left (3.78v per Cell left- Charged initially to 4.06v per Cell)

    I Estimate I should get around 65 to 75km range (Pas Only) on the above mentioned type of Trails

    Slowly increasing Charge cut off Voltage from 3.98v per Cell (first Ride) to 4.08v per Cell (15S Pack) with each new Charge/Ride. "No Over Voltage Error codes or Motor Temp issues" (Using commonsense dropping down to low gears up steep hills)

    Currently my Battman Wattmeter is reading 61.0V Total Straight off I-Charger at Charging/Balancing to 4.08V per Cell

    Big Thanks to Rodney (Luna Mate) Gary/Paxtana from Luna Cycles for all your help & Knowledge during my Build.

    - E-Bike Walk Around Video link

    - E-Bike Charging/Balancing Walkthrough via I-Charger 4010 Duo (No BMS) (Part 1) Video link

    - E-Bike Charging/Balancing Walkthrough via I-Charger 4010 Duo (No BMS) (Part 2) Video link

    - Custom Enclosure & Plug for Cell Log 8M Cell Checkers

    I will post links at a later date on parts I used to help anyone wanting a build like this.
    Last edited by Patrick1977; 5 hours ago.

    Here's a few more pics


      Plugging in & Charging E-Bike with I-Charger 4010 Duo (Plug & Play Setup) & Led Headlight operating (Photos)


        Finally hit some Trails, A good mix of Bush & State Forests to enjoy
        Last edited by Patrick1977; 2 days ago.


          Very nicely done. Q: why do the trees have no bark?


            You don't have eucalyptus in MI? LOL

            That's what the bark looks like on them...


            • max_volt
              max_volt commented
              Editing a comment
              Ah, that would explain that lurking koala.

            The actually shed there bark from time to time, depending on the Species of Eucalyptus Tree (No Koalas lol) There getting rarer unfortunatly thanks to Deforestation etc.
            Last edited by Patrick1977; 1 week ago.


            • AZguy
              AZguy commented
              Editing a comment
              We got plenty of them out here... nuisance trees...

            Luckily there are no "Drop Bears"


            • max_volt
              max_volt commented
              Editing a comment
              No one expects the dreaded carnivorous koala.
              I believe the only shedding tree around here is the odd sycamore.

            When I worked in Brisbane the koalas were considered dangerous.... they wander across the roads and cause accidents...