How to build a beast 5kw ebike from a 1.5kw aliexpress hubmotor kit

detailed video on how we built crazy powerful full suspension ebikes for dirt cheap
parts list:
ebike kit:
NZ$ 212.90 24%OFF | MTB E-bike Kit 36V or 48V 20"-29" Electric Bike Conversion Kit with 250/350/500/1000/1500W Hub Motor Double-wall Alloy Wheel
a.aliexpress.com/_m0DUShk
Hubsinks and statorade:
hubsink.com/products/heatsink
hubsink.com/products/genuine-...
QC sticker:
NZ$ 10.22 30%OFF | 6PCS/LOT 48V500W Bafang Mid Drive Motor Sticker Electric Bicycle Conversion Kit Sticker For BBSHD BBS System eBike Motors
a.aliexpress.com/_msRmZQK
the giant DC mountain bike was bought locally and the batteries are made from recycled tool battery Lithium ion cells
check out our other videos for the test ride

[@ThomasTheFapEngine]

This is awesome. As a Tasmanian rider with a max legal power of 250w, my favourite part just might have to be the sticker though... ;)

[@matthewallen1394]

Dude.. is that everywhere I just bought a 5k kit of Alibaba and now I can't ride it.shit Jervis bay oz

[@johanandersson2165]

@@matthewallen1394 add a fingerprint sensor. ill bet there is some Relays & Arduino that can be used, "locked" 250/300W 25km/h & unlocked max speed/torque and "dead mans switch" remove thumb and lose power.. use it smart and you'll never get caught.

[@beachcomber2008]

@@johanandersson2165 Awesome.

[@beachcomber2008]

_"might have to be the sticker though"_ - if it's in Chinese it might not matter that much.

[@johanandersson2165]

@@beachcomber2008 google translate on phone ? just add a fake 250W sticker they sell those too.

[@richardfraser-brenchley7297]

you legend awesome just what I needed to actually do the same thing but was really stressing about just about to start mine thanks for taking the time to make this

[@hrideshbudathoki3380]

did ya make it?

[@lIlIlIlIlIlIlIlIlI]

@@hrideshbudathoki3380 of course he didnt, just big talk on the internet

[@edatkins27m]

Im doin same thing to my voilmart i have 36/48v 50a brainpower controller n 2. 17.5 ah batt getting 48.7 mph the heat i drilled holes now thinking rc moror fan inside hub mounted for cooling or a 12 400w car cig lighter plug in dc to ac 110 converter has a small fan 12 v might use also

[@bengoodluck1858]

@Edser electric I love how many replies you have given to people with questions. Great job helping the E.V community.

[@jd-dc]

Thank you, that is what I am hoping to achieve with my videos. Showing just how easy and cheap it is to make wicked electric toys these days, which hopefully helps to build the community ✌

[@romant.2761]

@@jd-dc hey bro do these kits come with the battery or do i have to buy on its on if so where do i buy

[@accard1no]

absolute g thank you for taking the time make this, epic dude!

[@ChapuzasconRober]

Awesome job!!!! And the video with the footage is crazy!

[@Marxoszuza]

Amazing build!

[@jeanterine4712]

Best ebike diy video ever!

[@pb5625]

Keep them videos cooming 👍🏽😁

[@johnsheetz6639]

This is the best ebike video I think I've ever seen even with the music the talking can be distracting I want to do this for a living now!

[@MRAI503]

U r truly a mechanical engineer bro 👌🙂👍👏

[@bruzza3031]

That's a big job you made it look easy

[@MainelyElectrons]

This bike is epic, love the cooking mod

[@jasonbrown467]

i shunt modded my 3kw controller, before the mod it would do 75v x 60amp for 4.5kw, i did the shunt mod and got it up to 75v x 90amps for 6750watts, it lasted 3 nights of easy riding and about 5 miles total before it blew caps and other things on the board. i since then got a much bigger "3kw" controller that i think was marked wrong as its so much bigger and heavier, can go up to 114v and a max of 80 amps for 9.1kw, i shunt modded it too, but honestly i didnt even need to and its built like a tank, i have put a few thousand miles on it and i push it pretty hard sll the time

[@novaturbkkk]

How fast does it do. How much do you weigh. Where can I get the parts

[@jasonbrown467]

​@@novaturbkkk with the old controller i had it up to 60mph one time to see how fast it could go, it had a bit more power in it but 60mph was already too fast. i have since upgraded both the controller and the motor. weight really isnt the issue with top speed btw, me and my bike are heavy. i am stronger than average and can barely pick the bike up if its fully loaded with all the battery and gear, plus its awkward. i started with a 3kw rear hub kit from ebay. just find the size wheel for your bike, get that kit, and get a battery. batteries are expensive, and i normally only go about 30 to 35mph, anything much faster and it becomes too stressful

[@overlystrategic]

My favorite part of this is unlike the other madlads doing things of this nature you, like myself actually wear a HELMET.

[@marcinnae-bikeu]

nice modification and cheap. keep it up

[@jaden9389]

What battery did you use to build the 1500w bike originally and what’s the top speed and mileage?

[@RoadRunnerMeep]

Now that's an extreme mod, I like :)

[@ebikeunlock]

NIce work on the shunt ! :D

[@jd-dc]

Thank you, it's crazy how much this controller can handle

[@SpearoKC]

haha ripping on that little track above Harry shaw way!! Great conversion, keen to do something similar cheers for the info!

[@djsmootheuk64]

Giant ac most versatile bike in the world had 3 of them from cross country to free ride they do it all!

[@rotormandan2657]

I have to try this with the aostirmotor s17,nice video my friend!

[@dimonik12]

Dammit... I knew the little motor had more in her. I built one last year and went with the bigger QS motor as I was not 100% on the tuning, I ride at about 6k max anyway and the lower un-sprung weight on the back wheel would easily make up for the diff. I have recommended to so many people to get the little one and try something like this but I have never seen it done. Nice.

[@robertbrawley5048]

I lliked the music starting @ the 8:40 . By the near the end I was loving it

[@threedog575]

It's so delicious it's like adding more cooling to a gpu or something but for fellow traveling

[@DigBipper188]

protip: If you want even *more* power, it's possible to do a cap and FET swap for 100v rated components. the bones of these generic motor controllers is capable of taking north of 88v if you spec the right MOSFETs and main capacitors... Before changing over to a pair of VESCs, I used a pair of shunt, cap and transistor modified controllers on a 76.8v LiFePo4 battery for a total power output of about 6kW AWD... from bone stock 1500w motors as well. They seemed to handle 3,000w at that voltage shockingly well since I never ran into heat issues or even hot phase wires on both the stock motor controllers (which were a pair of 500w jobbies initially), or the motors.

[@MrJasenstewart97]

I have a Mac chain drive motor that was originally only rated for 48v 1000w but I've pushed 72v 7.5kw throw that thing and had zero issues yet, just hit 200miles on the build too

[@eonreeves4324]

@@MrJasenstewart97 i just got a 500w cheapo off amazon and i already suspect that it can handle much more than it's getting. In the setting I was able to disable speed caps and was able to go from 20mph (locked) to topping out at 27mph with the stock 48v battery. After riding it wide open 6 miles to work, the motor hub isn't even warm to the touch. It doesn't seem to be working very hard. I am new with ebikes but I spent a lot of time building 10th scaled off road rc and you knew when you were stressing the system when the motor was too hot to touch for more than a few seconds lol, that was the in field method of checking the stress on the motor with whatever gear ratio/battery setup you had going. point is i would run 3s into a motor that was rated for 2s and beat the living hell out of it, competing with motors that cost 10x more no problem lol I am thinking about dropping a 60v in it and see what it does with that. After that point i will need to get a different controller in it if I wanted to go to 72v. The stock controller can be set for 36v 48v 52v and 60v I have a target of ~40mph with this particular bike and I am going to see if we can do that on the stock hub lol

[@mickyb.8014]

​@@eonreeves4324did it work, I'm interested??

[@eonreeves4324]

@@mickyb.8014 haven't tried it yet lol the battery pack is pretty expensive. I'll get to it eventually.

[@mickyb.8014]

@@eonreeves4324 oh ok, well thanks anyway, I'm thinking of getting a 1500w 48v rear hub kit to slap on my 26" mtb, I'll be getting a 52v triangle battery, hopefully 20ah as it's all hills here in the U.K where I live... I'm just trying to gather as much info before I buy a kit/battery... Kinda torn between a Voilamart or maybe a ebikeling kit, if you have any info on which is the best affordable kit it's greatly appreciated... I'm expecting to pay no more than about £650 (got bike already) for the kit and battery. Cheers.

[@VROOOMIN]

sick ass build

[@jd-dc]

Thanks bro! It's an ongoing experiment, I'm going to cut out the top main frame bar and use carbon/kevlar to build a stealthbomber style battery box in its place soon so I can add more batteries, thought I better add some cooling first though

[@petermelnyk7664]

Man that statorade ain't no joke ...proof is in the pudding

[@LanceAlot247]

I wish I had the tools to do this! I may have to resort to purchasing one already assembled.

[@georgemc1030]

this adjustment is very interesting. can this modified control unit still have 3000 s hubsink and ferufloid ?? how many volt batteries do i need for this unit, thank you for your reply

[@michelbisson6645]

so if we change the whole controler???as probably it comes with the new 5kw motor, and what do we do with the battery?

[@BabylonPatrol]

awesome. thanks!

[@beachcomber2008]

That was useful. Thanks.

[@CheffHD]

your welcome

[@williamhadikin8658]

this what i need

[@sams5803]

So epic!

[@Jack77169]

Got damn sick video bro , I have the same kit 1500w 52v on my fat bike and always wondered how to make it acceleration faster, do you think I can get away doing this mode without using ferrofluid? If I'm not planing to go full throttle all the time. Thanks dude

[@jd-dc]

Awesome bro yes definitely, you just need to keep an eye on the temperature of your motor and controller, and make sure the battery can handle it. I ran it like this for a year with no ferrofluid or hubsinks and I couldn't see any obvious heat damage when I opened it up. Depending on the type of solder you use and how much will dictate how much the power will increase, I used 50% lead solder for minimum resistance, maximum power

[@lianhaggis5699]

how do you ensure safe charging? would it be at risk of exploding? how about if left on charge too?

[@lovysatisfy3264]

Nice bro

[@TheOriginalCoolDad]

Does the statorade interfere with the Hall sensors at all?

[@GrandHighMarshall]

How big a battery pack to you build? I love this build and I'm keen to buy a suitably sized battery pack.

[@snapihansen]

hi JD-DC. Im new to tinkering with ebikes. i just bought this kit you upgraded. Before you tinkered with the shunt in your controller. did you run higher voltage on the system than its rated for? I can easily build any battery pack, but i was wondering if i should build the battery pack with a little higher voltage, than rated.?

[@WimHaakZeeland]

Nice work. Curious for measurements. Recommendation: remove the yellow black connector. Mine caused a controller fail. The one with 3 wires where bolt and nut connect

[@jd-dc]

Thank you, yes good call I have heard that they can fail, I've been looking for a suitable 3 pin plug but most of them are pretty small so I'm thinking about using 2 xt90s for the 3 phase wires. It's a 205 hub motor, KS brand on the side of the motor.

[@WimHaakZeeland]

For the plus 30 A I am experimenting with big plugs. I cannot find a name. They can be bought on Ali. Plastic big car plugs.

[@Yomomsaltima]

That’s where I just got 12 pairs of brake pads for my aventon level only site that has correct ones by pic!, took about 20 days to get but I got 12 pairs for about 21 dollars the same price as the bike shop charges for one pair normal price

[@IVANMTB]

Buen video amigo. Yo la mia la tengo limitada!!!

[@wontonedits6166]

So can I under volt the controller bc I want to use my weekwacker ego batteries?

[@aliakbari437]

paint inside of the motor in dark black. the shell absorb heat much more

[@kevinduprey9326]

On the engwe x26 bike … your opinion on simple upgrade to 50mph bike?…. Basically a typical rear 750watt with weak controller…main goal is better response on throttle. Am I better off replacing controller or fusing it like you did?….thanks

[@randallschrecengoat1671]

what do you mean half throttle for double power?

[@mikeneitte212]

there is an 2 part epoxy thermal glue I used on custom built heat sinks for ram and other components..never tested it against a clamp system and thermal paste but did see drops in temps with ram on video cards and computer ram..there are different grades of thermal paste that work much better than just 2 dollar generic thermal paste..Artic Silver is the best I have found..btw he did use to much paste..more is not better..then thinnest coat possible is what is best.

[@mauricioximenes899]

Well done, I´m trying to adapt somethjng similar, a 48v motor on a 17" motorcycle rim, it´s extremely hard

[@catrellchase3392]

Hey mate great build what voltage is it running at now

[@petertothRC-FPV]

Nice work 👍500w sticker 🤣

[@parkerazz4385]

How to you keep your batteries from heating up pulling 80A!

[@valival_and_tine5576]

Following your advice for the controller I made it to pull 130A at peak. A bit too much. Not saying I don't like it but my batteries bms are 50A each

[@Clystuff19]

Hello! How many NM torque have at this time? And max speed?

[@safwanhazem1097]

Hi there, just popping by to see if anyone can help. I've purchased a 250w e bike conversion kit. Currently I'm getting the 03 info pas error code. Everything else apart from motor seems to be working, any ideas?

[@giannisaivatzidis7845]

Awesome vid. What batteries did you use?

[@angelme5692]

Hello. I have already built a massive 48V battery for this kit and I wouldn't want to build a new one for increased voltage. Do you think there will be benefits just by doing the higher current mod? Also, could you please tell me how many magnets does this motor have? I seem to have wrong settings in my bike computer... I don't know what number to put in the P1 setting... (kt-lcd3 is the display/computer) I also don't know what to do with the P2 setting :"D

[@campoint.x1032]

Does such a Controller work sensorless without using the Hall sensors?

[@wobbers99]

SUPERB. i got a FOREKNOW fat bike and put 1500watt motor and controller. 52v 21 amp hour Battery. It's a heavy bike. up hill 24mph .. down hill 45+. i need more torque more than distance. This is will try. PS... i have seen people fill the controller with a heat conductive resin to dissipate the mosfet heat to the outer casing... any thoughts on that? Thanks.

[@axelthorfilms]

On your 12 AH battery what is the continuous. No where near 80 amps i bet . If so what cells you using? Batteries wont last long may even burn.

[@Ibdrekly]

Great video I've built an e scooter using a 1500w 20 inch wheel kit running 48v 17ah battery if I just solder the shunt together will that give me more power? I'm a Newby to electrikery tinkering.

[@jd-dc]

Yes that will work, just make sure your battery can handle the extra power. There are lots of videos on youtube of people doing close up shunt mods if you search "shunt mod" you will find some more in depth instructional videos

[@isaacmccliskie4773]

Love the video just a quick question I’ve got a 1000w kit with the shunt mod so by doing the ferofluid in the hub will make it higher the the 1000w? Cheers

[@neutronpcxt372]

What the shunt mod does is allow the controller to draw more power from the battery pack. If your controller supports the extra load(always check!), then that's great. As for what the ferrofluid, it is used for decreasing the thermal resistance of the motor to the outside, allowing it to be cooled more effectively.

[@aski1529]

Do you think it can handle 30amp cont and 60 peak without the heatsink etc

[@chrismartin6427]

Quick question what was that black liquid you were putting in the Hub motor and what does it do

[@spade7754]

in my area e bikes are highly illegal but no cop can catch me thanks to this😂😂

[@attackscorpion5323]

I have a 1500w/52v system with solder shunts, but I’m not able to get passed 26amps. I wonder if there is anything else on a control that restricts amp flow.

[@dagnisnierlins188]

If its sw900 controller, in settings menu, go to p14 and set it to max amps your battery can do.

[@HeathenRides]

Is it OK to do drops and jumps etc with a massive hub motor?

[@irhcat-tauhid3174]

I ordered a 36v 20 ah lithium battery befor months. It didn't deliver it ant respond

[@Whitty2304]

The reason for it being hotter is that the bro will be running flat out top power instead of the less draw of your bike to achieve the same outcome making the less powerful bike straining and your product cruising more gently

[@charlesmaybank6323]

Your a legend 👏...please can you tell me were to find the road legal 500w stiker..as I was looking yestoday on line ..to no success. Only found 250w ..wich I won't get away with

[@dark_pumpk1n755]

hey thanks a ton for this video, i just have one question, do you thing it is possible to do the same to a 1000W motor? thank you so much for the video!\

[@jakesonewheeladventures.3976]

Man I’m looking into doing this to my mountain bikes this is my first stab at this I’m confident in my tinkering skills as I work on me and my buddies one wheels and I’m not afraid of working on electric is this something that a beginner is capable of ?? Any tips would be greatly appreciated or any Improvements or things you would have done or gotten better I would love to know I want it to be powerful and a blast on trails like I do my OneWheel so I’d love for it to be able to do 40+mph thanks for this video and the secrets !!!!

[@Debbiebabe69]

The bike side of things is more technical than the electronics, you need spanners, allen keys, and a crank puller (they are very cheap if you dont have one), as for electronics, unless you are modifiyng the kit you probably only need screwdrivers - so yea, as long as you are confident at stripping down and re-assembling a bicycle, the electronic side of things is pretty basic.

[@sandracannizzaro3037]

Do you reckon that can be done to a 1000watt engine soldering the two bridges together

[@jd-dc]

Yes, you should be able to shunt mod most non programmable controllers. Just make sure your battery will handle and be careful not to generate too much heat with the extra power

[@james10739]

I would think you would just need to hope it has good enough components to handle the power

[@rcaddictshow1288]

Great video.

[@mehmetalbay308]

How many mm are the phase cables and how do they withstand this much power?

[@michaelprice3031]

Was thinking the same thing

[@johndipietrantonio3701]

ive got 3 shunts side by side. Which do i connect?

[@hrideshbudathoki3380]

man i could just kiss you right now going to turn my old dirt jumper into one of these

[@cool50500]

outside 30c inside 100c,inside temp sensor is a must.

[@Debbiebabe69]

What is and where do you buy 'Statorade'? Also, know anywhere selling 250w power stickers???

[@coreyzladdin]

How fast did you get it up to you never mentioned that? Also could I do the same with a 350w kit to test the theory try get 350w to 1kw atleast I already have a 1kw bike but it’s for work

[@VQBulletProof]

That’s where I get all my brake pads hub motors etc etc they send it

[@emanuel601johnson]

Bro how are you filming yourself riding the bike? the camera turns and everything 👍

[@ryanaalderks1228]

What's the distance you can travel on full charge

[@bruzza3031]

Statorade fluid wow

[@13orangeleaf]

Nice job, do you still have this build running good?

[@waviestblock2529]

hey do you know if there is a hub motor kit for BMX bikes??

[@revparsons3tl]

Hi I've got 4 shunt in mine what do I do

[@MainelyElectrons]

Which heatsink kit did you order? I see they have quite a few options. Thanks!!!

[@MainelyElectrons]

I ended up going with the QS205 and it fits great

[@gaborbotschner6285]

Hi ! I recently bought a wheel of this type, I did everything as you did. But the wheel turns in the opposite direction. What do you suggest I do with it? Thx G.

[@motosk8er2]

Reverse any 2 of the motors 3 power wires.

[@thercchannel5757]

awesome

[@howardthomas3862]

do the stickers work , should have been 250 for uk .

[@marthamryglod291]

If the controller can put out 80 amps, what does the battery need to be to get the performance increase?

[@marthamryglod291]

@King Rafael cool. Thank you. So, oversize the battery for long life. I just built a Samsung 20s5p with a Daly 80amp BMS but the cells are rated for 175amp constant, 200 peak. I spent a lot of money in this pack and didn't want to kill them early.

[@E-BikingAdventures]

I was going to ask where can you get stickers like that, then I checked. They have them on aliexpress.

[@lovroperak7635]

Awesome video! Do you think i can do the same with my golden motor magic pie external 1000w?

[@CheffHD]

no

[@RIDE4LIFE6]

if i did this on a 1kw kit and used a 2kw battery. Would it break the battery or just pull 2kw

[@neutronpcxt372]

It would just pull 2kW from the battery pack.

[@jamesworkmail5]

what are the tools i need for this?

[@lezbriddon]

Plod will love this.... Once you go over 250w it's a motorcycle, expect some fines and driving licence points unless you disguise it well...

[@way2stupid37]

Hey how much did you spend on the battery and what would be the output of wattage if you saudered a similar 3000w motor like that?

[@jakegarrett8109]

The ESC controls the power, not so much the motor on these ebikes. Its shunt is there to regulate and limit the max power, so most likely you'll get the exact same performance (obviously with the caveat of any efficiency difference, and assuming same kV values).

[@romaingaultier239]

hi i would like to do like you i have the same motor and esc when you make the shunt on the 2 bars you put tin along the entire length? And do you think I can use a 72 volt battery? Can I reach 5000w? thank you for your videos 

[@ianmangham4570]

Volts x Amps=Watts

[@shaunphillips6160]

Love your work mate!! Hey are you, or have you, looked into lithium polymer batteries to lighten the bike up??

[@jd-dc]

Yes my friend runs his on lipo batteries, they are great. I am building a new battery from 21700 p42a 4.2ah cells

[@jasonbrown467]

lipo are less energy dense that lithium ion so they are a tad bit heavier, but they can deliver more current and charge faster, i run with 3kwh of lipo 66.6v x 44ah

[@Agilepickleunite]

@@jasonbrown467 66.6 noice