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Also put together a test battery pack using 24 x 15ah Headway cells to do some bench testing.

I struggled trying to get the controller to do the angle identification setup and control the motor but got there in the end. I did swap the positions of the hall sensor A and C wires in the connector so they matched the controller connector side. That didn't seem to fix it straight away but after running the setup step and few more times it eventually worked. Whenever the angle identification setup finishes it puts out a buzzer alarm code 3,2 which is for internal reset which isn't very intuitive. It might have been working a bit earlier as I didn't test the throttle every time it finished, thinking it hadn't worked because of the alarm!

One problem I've run into is the gap between the brake rotor and the motor is pretty small so the original brake caliper doesn't fit!
I contacted QS Motor and they recommended a few from their catalog that would work. Ended up getting this one in grey. I'll need to get a new mounting bracket made based on the original design and this new caliper.

What is the energy density of the finished battery pack? (Wh/kg)

francisco.shi wrote: ↑

Fri, 31 May 2019, 07:32

What is the energy density of the finished battery pack? (Wh/kg)

According to the specs, the Headway 15ah are 105 Wh/kg

Is that after it is assembled with the bus bars and holder?

francisco.shi wrote: ↑

Fri, 31 May 2019, 10:50

Is that after it is assembled with the bus bars and holder?

No that’s just based on the specs of the cells. This is just a temporary pack that I’m using for testing. Still haven’t decided exactly what the final pack will be.

Had some awesome help from Danny Ripperton (AEVA member) machining the swingarm blocks that hold the hub motor axle.


The blocks are solid aluminium and weigh 344g each

Put the new blocks into the existing swingarm, swapped the tyre over and got it all into the bike. Next step is to work out how to mount the batteries and controller inside the frame. Decided to push the bike home from the workshop and got some interesting shots on the way