Building a 10,000W Hyper Ebike (Tesla Battery)

It was funny editing this video and looking back at the bike before it was clapped out and covered in mud.
----------------------------------------------------------------------------------------------------------------------------
00:00 Unboxing the frame
00:37 Unboxing the motor kit
01:07 Disassembling the Tesla battery
02:58 Mounting the controller
4:00 Rear break is goofy
4:46 First test
6:07 Building the battery
8:55 Quick mods
9:27 Installing the battery
9:47 Programming plug
10:23 Front wire cover
10:40 Some quick jumps
10:49 Installing Hubsinks and Statorade
12:16 "Testing" the bike
12:49 Fixing the bike
14:00 Modding the controller
14:20 Breaking the bike some more
----------------------------------------------------------------------------------------------------------------------------
Editor used is Davinci Resolve

[@Calthecool]

Because everyone keeps asking, the build was around $3,100. In part 2 I will do a detailed breakdown on what and what not to buy, and if building one is even worth the effort (spoiler: you can buy them mostly assembled from AliExpress for cheaper so building one is only worth it if you love building things) I’m not normally the type to ask for you to subscribe, but I have 3 other projects I’m working on currently that are similar to this and the videos doing well helps motivate me to build more stuff, so hit that button! Also, I’ve learned a lot about building battery packs since this video, would anyone be interested in a tutorial that goes through the thought process of making a pack?

[@GravitySandwich]

sellout :P

[@Calthecool]

@@GravitySandwich Yeah I know, it hurts my soul to comment something like that but this video is doing too good to pass it up. At least I didn’t say to hit the bell 😁

[@GravitySandwich]

@@Calthecool Haha i was just joking anyway! You earned my sub :)

[@charliejason9615]

ye an me (uk) leaning this shit aint much on Internet so always good to build knowledge defo checking out other vids

[@Calthecool]

@@charliejason9615 Yeah I was in that same situation, and there isn’t too many build videos of these bikes so that’s one of the reasons I made this vid.

[@Kovanoid]

"My brother hit a small jump" *video pans to the bike in three pieces*😂😂😂

[@Spiros219]

this video is way to good for only 92 views

[@Calthecool]

That’s usually how it goes. It’s getting some more now. Meanwhile the 17 second no editing no commentary video I posted on a whim has 60k views, you never know what will do well.

[@ayon3x]

@@Calthecooljs a vid suggestion to also save u some money and it’d be intresting can you try to make a budget e bike? Usually in the past i can get the price pretty low by thrifting old bikes and getting cheaper controllers and battery’s but u seem a lot more experienced then me 😅. I’d love to see it and great vid btw ur underrated asf

[@Spiros219]

@@Calthecool i was early that's why it had 92,

[@teodorrusnac2777]

Now 2,9k 😮​@@Spiros219

[@Calthecool]

@@ayon3x Yeah I am interested in doing that, but I can't decide whether to use a new cheap bike or a used one off marketplace. In a lot of videos like that, the person finds a great bike for like $100 or already has one and that's the main reason the build is so cheap, but most people won't get a deal like that. I was thinking about buying one of those cheap moped style bikes and upgrading it, maybe keeping the budget under $1900 for a 6000w ebike.

[@Trailtested]

Hats off to you for committing to that full long build of a mystery bike. Coming from a seasoned motocross rider and KZbin reviewer I cringe to see that suspension snap.

[@notsoren665]

I love the rough riding and crashing. Really shows where the weaknesses are in the construction

[@Karairoo]

I like how he doesnt even explain anything, just goes right to the point

[@rasmus1600]

Damn you guys abused the hell out of that bike. I've taken mine on trails and MTB courses and no damage other than rust.

[@Calthecool]

Yeah, I'm not the easiest on stuff because I like to fix things so I don't care if they break. We were jumping it to flat and all types of stuff.

[@cnr420]

bro, you have an insane amount of knowledge. This was crazy I wish i could add +1M views. keep up the incredible content.

[@Lil-San]

Bro you had fun with this that's all matter, more to come! this is good project 😎

[@stockey]

That's a hell of a BMS you have there.

[@lemonsqueezexd5468]

Insane project you got there man, thanks for sharing it with us! Looking forward for part 2

[@jimbos5.7x28]

Well friggin done my man! Get's me pumped to start building my own.

[@jujuboi2302]

This was an awesome watch. It was hilarious seeing it get destroyed & then just fixed up again. Glad you’re using the hell out of it. Keep it up!

[@finnmorrey1406]

Bro keep posting this videos sick and surprisingly good quality for a small channel

[@y0wl0o64]

This desveres much more attention.

[@NickPCage]

showing how hard u rode that earned my sub.

[@tj9959]

Crazy build for some crazy guys, you absolutely demolished that bike! I was super impressed with ur DIY skills. I hope to one day get on ur level!

[@MathieuTechMoto]

Great work, a range test in the future would be pretty interesting !

[@Calthecool]

@@MathieuTechMoto will do, that will be in part 2

[@_444voxeyyy]

ONLY 1.22K SUBS YOU ARE UNDERRATED!!

[@yurrfaris]

That battery is insane

[@Calthecool]

You haven't seen anything yet, the battery I make in this video can output the equivalent of 14hp, but people build truly insane packs that can output the equivalent of 80hp: www.reddit.com/r/batteries/comments/1dkubga/first_post_here_26s14p_p42a_936v_nominal_1092v/

[@stasi0238]

​@@Calthecoolhey try making simple arc furnace powered by those batteries using carbon rods for welding. It would be much stronger than simple furnace from wall output with the 12hp power. It probably will melt steel easily

[@Calthecool]

@@stasi0238 that would be powerful, I’ve messed with electric arcs with graphite with smaller lipo batteries but nothing this big.

[@stasi0238]

@@Calthecool I used cheap Chinese arc welder (3kw) as simple arc furnace and it melts every metal but has a hard time melting steel and the steel hardens in crucible before it can be used. Copper, bronze aluminium etc melts really easy. I think using such battery as yours you probably could melt kg of steel and use it to make things for bikes. Like print wave metal castings for handles and such.

[@yurrfaris]

@@Calthecool my jaw just dropped. im running 2kw, you're running 10kw, now 58.9kw???

[@ghxxtofxxcial]

Loved this Vedic he’s so amazing ❤

[@ahmonoss]

definitely great tutorial video with pretty good humor i’ll keep watching it

[@DivyangM]

Wow, thank you for not doing "Subscribe to watch how it rides" after building it. Great video.

[@Calthecool]

@@DivyangM I did kinda do that, but not by choice.

[@DivyangM]

@@Calthecool That's perfectly fine, otherwise how to grow the channel. But, some KZbinrs stop the video just after the build and then don't upload the next video for a month which is annoying. I personally enjoy the videos where something happens and then the result is in the same video. Anyway, hope your channel grows. Keep it up. Good luck. 🙂

[@nerdg2]

Damn, learned allot. I think i'm finally ready to take on a custom ebike project.

[@masoncochran5737]

the video ive been waiting for since tesla started getting big

[@nobody23.]

Underrated creator u deserve wayyy more than 1.3k subs

[@bigbilly29]

This was a great video, thanks for sharing

[@RastaOnABike]

This video has just inspired my ultimate bike build. I will be making one ASAP

[@Coldlegend214]

how does this not have more views crazy

[@albertlirbank7611]

dope shit, i recently made a emoto as well (although only 8kw) its cool to see how you did yours!

[@Calthecool]

8kW is powerful, this bike was 8kW most of the time I rode it and it was lots of fun.

[@Elissandro.]

broh u look so inteligent did, amazing video!!

[@jonathan-pw5mx]

This is incredible. Youre Gonna blow up man

[@XxBanziixX1]

Heyo, I work with high-voltage EVs and some stuff I feel like I should just mention as a safety. Please do NOT use solder on HV lines. The HV terminals are meant to be crimped. High voltage connection can easily get hot enough in some situation to melt the solder. It is industry standard to never solder these as it is a safety issue. I would also double check the bus bar size and thickness you are using to connect the cells together. Depending on how much current you pull through your pack, the bus bar (seems like you are using nickel or tin strips) may add a lot of heat you don't want. Very cool build and clean video! Keep up the good work!

[@Calthecool]

@@XxBanziixX1 I now know to not solder those wires, although it should probably be fine considering they are big copper terminals with 3 gauge wire. The nickel strips are 8 x 0.2mm, which I determined would be good enough after looking at a bunch of forums, all of which gave different values.

[@jonesy2009]

@@Calthecool just because the wires can take the current without getting overly hot doesn't mean you wont run into a situation like the terminal screw coming loose and causing a high resistance fault that heats the terminal and melts the solder.

[@Calthecool]

@@jonesy2009 ok, I’ll crimp my wires from now on.

[@RainbowSheep_was_taken]

This is really cool

[@mikebergman1817]

Subbed. Been wanting to do a project like this.

[@fenilkapadia6735]

bravo! what a way to check durability...... great skills man.

[@Smokey00]

lol dang you are full sending that thing dude

[@aeskellion]

I love the build, but “hyper ebike” brother that’s a motorcycle

[@Calthecool]

Yeah, it's somewhere in the middle. Depends who you ask.

[@ochenGsUp]

Great work with the bike mate!

[@Calthecool]

Thanks

[@TheTexasDuke]

Yall wild god damn 😂 yall put it thru hell

[@PHARAOH_89]

Wow that was super cool!

[@sams5803]

Dude epic! keep it coming!

[@bransonclayton]

Don't worry. If you don't have clearance. You will.

[@loamymtb]

Nothing wrong with a little self clearance!

[@glory298]

Great work sir! You deserve more subscribers

[@Calthecool]

Thanks! I had 500 last week so they are definitely coming in.

[@charlesb689]

Thanks for sharing! Great info

[@ebikehacker]

Just got the frame today

[@rainhodl3er72]

Loved the extreme riding to find as many as posible weak spots in your build. Not only a smart guy but also a serious bike rider. I hope you take care of safety and wear full protective gear while pushing your bike to it's limits. I look forward to seeing the build update and more riding from you

[@Calthecool]

@@rainhodl3er72 You are right about the protective gear, I was wearing 60% bike helmet and 40% full face helmet before I saw the suspension snap and my brother ragdoll, now I’m going to always wear the full face.

[@fenexj]

good vid, nice build

[@haywirerc]

Motorized bike is sick!

[@some_guy441]

1:00 "I'm not going to buy the battery...." then 10 seconds later... buys a huge ass battery.....

[@Calthecool]

@@some_guy441 “the” battery, implying a stealth bomber clone battery. I would love to just get one for free but that’s not happening.

[@tonyhussey3610]

Such an interesting video 😊😊

[@tubularmonkeymaniac]

Bro, such a well crafted machine, and the video was perfectly succinct. Could have gone even longer tbh. Thanks for sharing! Can I just encourage you to wear a fullface MIPS helmet? Speaking as someone who just got out of hospital for the 3rd time after a bad bike crash.

[@Calthecool]

@@tubularmonkeymaniac Yes I would have loved to make the video longer. I’m definitely wearing a full face from now on

[@LUCASMACHOWSKI]

I did similar build, tesla cells, sabvoton 72200 now on the bike vector ebike frame

[@Calthecool]

@@LUCASMACHOWSKI the vector frame looks so nice, that would be a fun build

[@TheMechanizedManiac]

the bycycle pedal make it look, funky, but sick build

[@ThoughtfulAl]

FAR better than my achievements, I just waddle from bed to the couch each day, and back again.

[@peakpineapplestudio]

Damn bro you really but that bike thru the ringer 😅 but I love watching people like you fix things again. My e-bike is no where near that damaged 😅

[@the_auyitboy]

this is the most custom build i ever seen

[@Calthecool]

@@the_auyitboy You haven’t seen many then, this one is pretty basic compared to some others.

[@samuraiscripts]

subscribed! nice video

[@Calthecool]

Thanks!

[@SAEChicken]

in my opinion a tiny bit of music in the back ground would make these vids be soooooooo satisfying to watch

[@Calthecool]

In my opinion the background music can be distracting, but I'll give it a try. I had to mute a lot of the clips so I know what you mean.

[@SAEChicken]

@@Calthecool like nothing to loud but everyone likes there own music 🎶 but I like to see this kind of content

[@johnsmith7676]

No music. It serves ZERO purpose in such videos. If you need to listen to music when watching a video like this, then you truly are a complete slave to the Matrix.

[@tarasn.6892]

To disassemble such batteries, you need to fill their plastic parts with acetone and wait 1-2 days, the plastic will become very soft, and the glue too, it will simply fall off the batteries. We did this when we assembled charging stations based on Tesla batteries. Also, you don't have to remove the fuses from each battery, it's enough to tear off the aluminum plate and the fuses will come off with it.

[@Calthecool]

@@tarasn.6892 ok, I’ll try that if I do this again.

[@caseymoto]

great job😆

[@mandrakejake]

Good video dude thanks

[@DaStuntChannel]

I have a FOX DHX 5.0 in the rear and a Marzocchi 888 RC3 Evo Ti in the front, they are smooth as butter, night and day from stock sus

[@davidstrancar7994]

Nice video and god work

[@suli_jo]

Very good video

[@leedchristensen]

10,000W sounds awesome but it’s only about 13.4 hp😂, nice work though!

[@ultrasonicbass]

Fire video

[@eBikeUnikat]

Ich hatte diese E-Bike auch 😎👌 und es was ein Traum 🤩💪 Leider kann man den Rahmen nicht empfehlen, da ich dieselbe Schwachstelle hatte 🥴 Cooles Video 💯💪

[@calebmoore8425]

I like the videos thumbnail!

[@jshireley]

So when are we getting Part 2?? Love the video man!

[@Calthecool]

New suspension arrives in 12 days, after that I'll start filming.

[@DaStuntChannel]

Front forks you can get used Marzocchi 888s, they are amazing

[@Tony-nl6pf]

Surrons rub on the break pads too, don't even worry about it. From factory to time to replace, they were rubbing on all 3 bikes I got.

[@AL-jc5xs]

It took me two hours to assemble my ready to go 15KW, 72V 56Ah Samsung cells, 200A controller and new wide frame.

[@BVLVI]

You get what you pay for when it comes to 18650's. That is such an important aspect of the build. For example I can really accelerate hard on my 7kw E-scooter it's pulls just as much as my camaro til about 20/30 mph, not to say it doesn't have top speed but E-scooters with road tires are INCREDIBLY SUSCEPTIBLE TO SPEED WOBBLE AT 60-70mph. "DON'T GET ROAD TIRES" I hit speed wobble twice and I wasn't wearing a helmet because I was just going down my own street. Anyway brother I have some High end LG cells I paid a butt load for but they make a HUGE difference in available power under load. I can go look it up if you want, let me know. Because your acceleration is looks to me about 3-4kw at best.

[@Calthecool]

@@BVLVI The only time I went full throttle in this video was when I was on the pile of gravel. I’ll show the acceleration better next video.

[@ENDOPRYSMyt]

Great video

[@Calthecool]

Aye the man himself! This video wouldn't be possible without your videos.

[@ENDOPRYSMyt]

@@Calthecool No problem man. and ayyy 12K views in 3 days, you have got yourself a million view video. make sure to get add revanue going. you can make a good chunk of the money back from what you spent on your bike just from this video, Im sure of it!

[@Calthecool]

@@ENDOPRYSMyt I’m nowhere near monetized, but I’m definitely going to turn it on when I get there.

[@ENDOPRYSMyt]

@@Calthecool oh interesting I thought they changed it to 500 subscribers and 2k hours watch time.

[@kokujins6931]

ur gonna blow up

[@PraetorAirsoft]

Very cool! But why does it sound so rough when spinning on a stand? Rear disc alignment maybe ?

[@Calthecool]

@@PraetorAirsoft yes it isn’t lined up quite right

[@felixb.59]

completely clapped it out after a month. legends 😂❤

[@Calthecool]

@@felixb.59 I prefer the term “testing to find the weak points” 😆

[@lapque]

you should try ohlins shock or a fox air shock on the rear!

[@Ronin-ib8rb]

Can you please put the links for all the parts in the description.

[@Calthecool]

I will on the next video, I want to discuss the parts some so you know what to buy.

[@_North]

> Didn't buy a prebuilt battery pack in attempts to sustain a budget >* Proceeds to buy a Tesla battery*

[@Calthecool]

It would have been +$800 to the budget if I bought one, they are super expensive.

[@_North]

@@Calthecool what did you do with the excess cells

[@Calthecool]

@@_North I put them in a Razor electric scooter. I’m actually editing the video right now, stay tuned.

[@_North]

@@Calthecool 🙏 I can't wait These videos are super entertaining

[@user-im8yv6ne4f]

hi....looks like you need a thicker fork...and be sure to check metal tempering....the more it gets super hot and cooled quickly ...the more brittle and harder the metal...practice makes perfect...keep up the good work...

[@mandalmandal4593]

lol talk about pushing things to the limit, this was priceless. thanks.

[@JasonNosajasoNosaj]

Nice build! Exclusing the battery, ariund how much would the build cost for someone else trying it?

[@Calthecool]

@@JasonNosajasoNosaj with battery it was about $3100, so maybe $2500 without it?

[@Coyote.five.0]

i know this might sound crazy but is it possible to retrofit a pc water cooled system into the battery compartment, thus making your system water cooled ?

[@Calthecool]

@@Coyote.five.0 yes you could probably do that but it really isn’t necessary. Maybe if you have a more powerful battery.

[@Coyote.five.0]

@@Calthecool thank you for clarifying 👍

[@user-vq7ue6vz4h]

BROO YOU NEED TO TELL US MORE INFO HOW FAST DOES IT GO HOW LONG CAN THE BATTERY LAST HOW MUCH DID IT COST YOU ARE anyways good vid bro keep it up i also want to know how did you learn to do that and is it possible for someone like me to do it at home

[@Calthecool]

It can go 45mph/72kph if I enable something called "field weakening", but it goes 40mph/64kph without that. It cost around $3100, but it's about to cost $3650 when I buy new forks and a rear shock. The battery lasts a long time, I can't tell you exactly how long because I haven't measured it. You could do something like this at home, but you would need a lot of experience and tools. I can do this because I've been building stuff like this for a while: kzbin.info/www/bejne/iKKWXqt-ba6DnZIsi=BR-WOU_wcyY8tDoj

[@user-vq7ue6vz4h]

​​@@Calthecool thanks bro i have some experience and i also know people that know how to weld and stuff like that so that is no problem but i dont know where to get a tesla battery where did you get yours i have no idea where to start searching and do you have like a patreon or some way i can contact you for some help tnx

[@Calthecool]

@@user-vq7ue6vz4h Where are you located?

[@user-vq7ue6vz4h]

@@Calthecool serbia belgrade

[@ianmangham4570]

Great patience and skill with battery 🔋 👌 👍 😎

[@joemulkerins5250]

Massive effort to build it. Immediately destroyed it. Fixed it. Destroyed it again 😂

[@Calthecool]

You can probably predict what's going to happen in part 2. The swingarm is already bending.

[@FluePeak]

Would be fun to get all the links of stuff you used, would be a fun DIY project

[@Calthecool]

@@FluePeak It would be cheaper to just buy one on Alibaba, but I understand how fun it is to build one so I’ll probably do a rundown of all the parts in the second video. What I bought vs what I would buy now knowing what I know now, stuff like that.

[@GapRecordingsNamibia]

I hope you tuned the controller to the motor? If not you will not be getting the full torque, cogging can also be heard especially in low speed high torque manoeuvres if the controller is not properly tuned...

[@Calthecool]

@@GapRecordingsNamibia it came tuned, it always ran really smooth except that one time when I got it really hot.

[@Calthecool]

Anyone have some recommendations for front forks and a rear shock? I would like to keep the combined cost below $650 if possible. The bike weighs probably 140Ibs? haven’t weighed it yet.

[@CristianBurr]

For that price, you can find something used from a more reputable brand. Good luck!

[@dunxy]

How much does bike weigh? Get some used mx stuff, from what bike, march up weight, you may need new triple clamps unless you can match up dia and mod your shock mount and/or swingarm but you're guaranteed reliable performance. Easily achievable for your budget.

[@WiPZ0rGaming]

Rear shock can be a DNM one, they are failry inexpensive and work great for the price, i see it installed on most surrons and bikes alike, aliexpress should have them for 200$ max, as for the front fork i personally have a Marzocchi Downhill fork, try to go with something that has a 100x15mm front axle as the DH Boost hubs are usually harder to find parts for as they are 20x110mm and most hubs are 32 holes.

[@Calthecool]

@@WiPZ0rGaming Would something like this work: www.aliexpress.us/item/3256804801913527.html?spm=a2g0o.productlist.main.11.6a09ZXBiZXBiA3&algo_pvid=c68e7080-e39e-4207-8083-509612e4c9f8&algo_exp_id=c68e7080-e39e-4207-8083-509612e4c9f8-5&pdp_npi=4%40dis%21USD%21720.00%21525.60%21%21%21720.00%21525.60%21%402101eff117205368404303667e103c%2112000031253792742%21sea%21US%210%21AB&curPageLogUid=wog0SQYCEeU4&utparam-url=scene%3Asearch%7Cquery_from%3A I would be willing to take it easy and avoid any big jumps, I really don't want to spend $1,000 on a front fork.

[@WiPZ0rGaming]

@@CalthecoolThis kit looks great and it should fit the bike without any mods, the only thing you have to be 100% careful about ia finding a wheel that suits the 20x110mm fork axle, orher than that it should also take a bit of a beating around forest trails.

[@jasonking8937]

Love this..

[@ianmangham4570]

That awful juddering when the motor gets hot is the 3 phase wires overheating 😮

[@ianmangham4570]

I'm glad you cut that big ugly stand block off 😅

[@throwawaypt2throwawaypt2-xp8nx]

thank you greatly for actually abusing the bike (like i would if i had it) and not babying it like most. luv to see the carnage and jumps, def stiffen ur shocks i hear them bottom out

[@Calthecool]

Your welcome. I've watched enough boring bike review videos where all they do is ride it on the street and maybe a dirt path, I knew I had to actually make this video interesting and show what the bike can and can't do.

[@throwawaypt2throwawaypt2-xp8nx]

@@Calthecool stay goated hyped for the next vid

[@user-vc6pl2hb4x]

There are no links to purchase, which is unfortunate

[@jiggilowjow]

hey for the brakes move the mount braket 180 ansd the caliper will not rub

[@jonasmeier417]

Great! How much is it approximately?

[@Calthecool]

$3100, but take that with a grain of salt. I will do a in depth breakdown in part 2 of what and what not to buy.

[@Tyblerone]

I think your caliper mount is on backwards for the rear brake.

[@Calthecool]

@@Tyblerone it’s on the right way, the reason it didn’t line up is that I moved the wheel back to tighten the chain.

[@mandalmandal4593]

I have a 52v 2000w ebike, its the Deepower 26H pro. that thing goes 55kph, rear wheel drive, 52v 25ah battery, what can I upgrade to make it go faster?

[@Calthecool]

@@mandalmandal4593 higher voltage goes faster, so probably the battery and controller.