Aggressive Long-Travel Enduro eBike Build: From Concept to Trail-Ready

[Freda]

Hey Freda, my initial plan was to go with the M820 motor, but I couldn’t get my hands on one. Luckily, someone here offered me an M510 at a great price, so I decided to go with that .

As for the linkages, if you check my earlier posts, you’ll find the full simulation along with the geometry values that I pulled from Linkage X3. In the CAD, I’ve started working on everything I can before scanning the motor, which is why the motor mount and rear triangle anchor points aren’t included yet.

Thanks for your feedback!

Oh sorry, I did see that post earlier and still forgot.. Yes that looks good, very progressive.

Your battery has 21700 cells? I built a ~500Wh and first opted for 21700 cells but then realised using 18650 cells take about the same amount of space and weight. The benefit being 3P configuration for 18650 to 2P for 21700 cells.

 

[Goff]

I have been thinking of building a intergraded battery in the frame as I wrap the batteries I build in carbon anyway, it means you can reduce weight, it’s stronger and the down tube is sleek.
Obviously the down side if you have a battery or bms problem you have to cut the frame, but I have had no problems with a battery yet and if you know what you are doing you can design it in a way to allow for a cut line to remove the bottom side of the down tube and repair the frame.

I think you should consider a range extender, 500Wh (18650 cells) will be enough, there is so much focus on having a big battery, but the weight penalty is not great, but with a 250Wh range extender you can have that extra range for big ride.

Just something to consider

 

[martinvb]

I have been thinking of building a intergraded battery in the frame as I wrap the batteries I build in carbon anyway, it means you can reduce weight, it’s stronger and the down tube is sleek.
Obviously the down side if you have a battery or bms problem you have to cut the frame, but I have had no problems with a battery yet and if you know what you are doing you can design it in a way to allow for a cut line to remove the bottom side of the down tube and repair the frame.

I think you should consider a range extender, 500Wh (18650 cells) will be enough, there is so much focus on having a big battery, but the weight penalty is not great, but with a 250Wh range extender you can have that extra range for big ride.

Just something to consider

The range extender is something i was already planning on. About the battery it will be an integrated battery with a carbon enclosure but it will be extractable trough the motor mount for serviceability.

 

[Thomas39]

Ciao, con 500 W a 1500 D+ puoi arrivarci solo in modalità eco e su strade lisce. Valuta un 600 W.
se si desidera installare un display sul tubo superiore, la forma rotonda potrebbe rappresentare un problema.

 

[martinvb]

Ciao, con 500 W a 1500 D+ puoi arrivarci solo in modalità eco e su strade lisce. Valuta un 600 W.
se si desidera installare un display sul tubo superiore, la forma rotonda potrebbe rappresentare un problema.

Thanks for the point on the screen. I'm aware of that and my workaround is to not have a screen at all. At the end of the day a simple matrix led for battery stat, 5 leds to indicate assist level and a couple of buttons on the handlebar is all that is needed in my opinion. Also less stuff that can and will break in the case of a fall...
With 530wh in combined use so eco when is not super hard and boost only in super steep areas it should be enough for 1100-1200m+ and if i go on a big ride i will be doing a range extender to clip on the bottle holder.

 

[martinvb]

Hi everyone,

Apologies for the lack of updates this month. I’ve been busy with other projects and couldn’t dedicate as much time to the bike as I wanted.

Today, I’m sharing the current state of the CAD model along with some key design decisions aimed at improving compatibility and ease of repair. For the derailleur hanger, I’ve chosen to use the SRAM UDH (Universal Derailleur Hanger) system. This choice ensures excellent compatibility with most SRAM drivetrains and simplifies component replacements in case of damage, which is especially useful for a bike that’ll be used in challenging conditions.

Motor Update: I recently received the motor, and I’m in the process of 3D scanning it. This step will allow me to reverse-engineer a precise model to integrate it seamlessly into the CAD assembly of the bike. It’ll also help in designing the motor mount accurately, avoiding any interferences and ensuring a perfect fit within the frame.

I’ll be sharing some early renders of the full assembly soon, along with more insights into these design decisions. Thanks for your patience, and stay tuned for more updates!