Triple your E-Bike Power? Here's How (Part 2 : Mods)

In this video we dive into how we are going to modify this Troxus Lynx to be 3x the power compared to original.
That may sound like hyperbole but the math works out to the bike being around 1,000W in stock form and we're going to up that to 3,000W in modified form.
To do this we are using the following components;
1) ASI BAC855 Advanced Motor Controller
www.affordable...
2) A Custom Made 24V Battery Add-on
3) Moped Tires for improved traction / safety (Shinkko SR241)
4) Significant Motor Mods, including welding the clutch so that the motr is able to provide regen braking, as well as sealing the motor with Automatic Transmission Fluid to improve cooling.
Shout out to Troxus for providing us with this bike!
www.troxusmobi...
Note : None of this is necessary, this is all for fun. Keep in mind this is more power than this bike needs, this is for the love of science and making.

[@kevinnashskitchen3517]

The other 6 people in USA that can do this are probably watching.

[@ElectricBikeLaboratory]

Hahaha! 😂 Thank you for watching !!

[@mwkeefer]

I am catching it late, but yep can do this and have watched :) The VESC controllers will suit your purposes no matter the power level or features needed, from 20-30a all the way up to 100s of pack amps.

[@brucevous1]

I hope dual motor Performance is in the works for future episodes! I got a beast of an ebike myself.... hopefully video soon

[@ElectricBikeLaboratory]

We've got one video of a 2WD check it out ! Thanks for watching :)

[@davidhazel36]

Hello, I have the new upgraded smlro xdc600 2000w dual motor ebike and have made a few mods. It will now do 39mph top speed and get there peeling out almost the whole way. Tons of fun. Atm I'm running 2 shark batteries both are 52v 30a one in stock location and one below the frame, a 120v x 120a dual battery discharge module, smooth tread tires, ive shunt modded both controllers, clutched derailleur, upgraded all power connections to xt90s, 8speed freewheel, 60t chainring, suntour suspension seatpost, c9 seat, wake headset and handle bar, a lighter backrack and fooker pedals. I've also increased the power wire size to and from the controllers to the batteries and shortened their lengths. I feel like this bike is capable of much more power and speed. Maybe time for new controllers and go to 72volt? Any suggestions on taking this project to the next level?

[@ElectricBikeLaboratory]

Sounds like a beast already !

[@hesamhayedi345]

Wow 🤩 Another powerful E-bike 💪🏻 Good job guys. Keep going. You are the best❤

[@ElectricBikeLaboratory]

Thank you Hesam!! :D

[@FloridaVolts]

Nice. I can’t wait to get my first e-bike

[@ElectricBikeLaboratory]

They are fun! :D

[@winkydee]

Classy looking Troxus. I'd be rocking a fullface helmet on that thing! Jebus!

[@ElectricBikeLaboratory]

Thank you, they are a sweet bike! Full face is a very good idea :)

[@joe-y1z]

Hi, how are you guys running 2 different batteries at their own voltages with different BMSes in series? From all i could find this is not a recommended setup. I currently have a 48v battery and would love to step it up to 72v this way. Super keen to do the atf mod!

[@RainBitcoins]

There's no possible way that will hold the ATF for a lengthy period of time... But deffinately an awesome build man!

[@ElectricBikeLaboratory]

Surprisingly still hasn't leaked out yet. And thank you!

[@WaterDR-tw8re]

Instead of lock tight, use 5100. It will be permanent.

[@ElectricBikeLaboratory]

Thank you! Well noted 😁

[@pauly51]

6:23. Is there a weight difference between motorcycle tires over regular ebikes tires?

[@ElectricBikeLaboratory]

Motorcycle tires are much heavier, but all the weight is in the added rubber , a worthwhile trade

[@rymalia]

5:49 - today I learned that bike tires are measured by OUTER diameter, and motorcycle tires are measured by inner diameter, so 20" bike tires are actually on 16" rims

[@ElectricBikeLaboratory]

Yep, you've got it!

[@dogdronesearchdd3782]

Awesome video I may do this to my motors.

[@ElectricBikeLaboratory]

Thank you! It was a fairly straight forward and easy process, surprisingly the ATF hasn't leaked out anywhere, other than actually going THROUGH the cable (which was surprising). Only a couple drops though. Thanks for the comment :)

[@electriclifeevc8183]

Don't recommend those welds will brake and or brake your shaft as they not strong enough like direct drive motors had 6 geard motors brake already

[@JoeCamel-fn7dl]

How fast is it if you don’t mind me asking, also, what is the different in clearance between the 2 inch stock tires compared to the 16 inch motorcycle tires? It seems like 16 inch versus 20 inch would be a 4 inch difference in diameter, but is there any difference in speed if that modification was the only mod done?

[@bfree6197]

16 inch motorcycle tires are the same as 20 inch Bicycle tires. Different way of measuring them, so the numbers don't match... but the size is the same

[@benchapel9814]

Cool that you can wire two separate batteries in series. Do you charge the two together with a 72v(plus) charger too, or do you charge them separately?

[@ElectricBikeLaboratory]

You can actually do either but in this case for us we will be using 2 separate chargers

[@IMBruceECLECTIC]

Mad scientists with Skills!! Great video!!

[@ElectricBikeLaboratory]

Thank you! :)

[@TheAkyles23]

Buen trabajo muchachos!, ya me gustaría a mi saber de electrónica para poder modificar mi e-bike!

[@ElectricBikeLaboratory]

¡Gracias por mirar y tus amables palabras! Estén atentos y seguiremos agregando más videos sobre la electrónica :)

[@hisforhack]

Interesting Video. When I use Silicon on gasket surface, I will only hand tighten it till the you have a silicon bead showing. Let the Silicon cure for 24 hrs before the final tighten. The cured Silicon will make better seal. Can you use a torque sensor with the control?

[@ElectricBikeLaboratory]

That's a great point, that would definitely make for a better seal. Torque sensor is possible with the ASI BAC855, we didn't go that route because of the torque sensing BB, personally I'm mainly a throttle only rider so it wasn't a huge thing for me. I know some people love true torque sensing though (such as yourself!) Thanks for the good comment!

[@andykerr3803]

Would like to see a comparison to air cooling the motor.😊

[@ElectricBikeLaboratory]

Me too , it's in the plans ;)

[@andykerr3803]

Some guys actually drill the hub for ventilation...​@@ElectricBikeLaboratory

[@frankroach9346]

I like the way you connected the battery and? are the batteries the same voltage

[@ElectricBikeLaboratory]

Not same voltage one was 48V 20AH and other was 24V 20AH but same cell spec and capacity so they drain equally when connected in series. Thanks for the comment ! ☺️

[@hobohank2040]

What size and or brand motor cycle tire can I use to replace a 26x4 tire?

[@ElectricBikeLaboratory]

I dont think 26s have any motorcycle tires that happen to line up perfectly. 20in bicycle and 16in motorcycle are in that sweet spot where they line up and I believe 18in motorcycle and 24in bicycle also but I'd have to confirm

[@hobohank2040]

@@ElectricBikeLaboratory Thanks for the info.

[@NavinJohnson_thethird]

Time to replace that vise.

[@BeeneUSMC]

Is the motor proprietary?

[@ElectricBikeLaboratory]

Bafang G062 common motor that can be bought :)

[@magiricod]

Sick vid what pants are you wearing at the end lol?

[@ElectricBikeLaboratory]

Haha they are my favorite! They're an amazon buy, here is the link; www.amazon.ca/gp/product/B08KDHDZVD/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

[@Mikker30]

Hope we get to see speed run

[@ElectricBikeLaboratory]

I got it going 60km/hr which was plenty , it had more in the tank though 😉

[@Mikker30]

@@ElectricBikeLaboratory 60 km that’s nothing all that work and money I have a 48 volt 750 watt motor that does 52 if I pull regulator wire it will do 70 kph

[@ElectricBikeLaboratory]

It spins to 99 , it'll do about 70 but I didn't care to push it that fast with the brakes and no rear suspension. Originally did about 45 so vast improvement. All the work and money ? Haha the work is fun and I'd do it anyway, and this bike was given to us for free and we spent a few hundred on mods. A bike that goes 70kmhr for a few hundred bucks I'll do all over again in a heart beat 😉

[@KennyLaBean]

you gotta use transmission pan sealant tranny fluid eats every other rtv out there has to say transmission fluid on it

[@AnthonyLee-t4g]

I would like one of thouse bike some body canbought one for me nice job❤

[@ElectricBikeLaboratory]

Thank you!

[@pedrofernandez8729]

For those who wonder why they're coming up with new laws and regulations re e bikes, you know why.

[@wmosteller]

Dope mods. Like to rewire a 48v 20ah batt to 52v myself. Havnt ever thought of that mod and or seen summin like it done. coolness

[@ElectricBikeLaboratory]

Thank you ! 👍 Glad you liked it ! 😁

[@Funermen]

Hope we do get a 3rd video in this series showing off the difference the ATF fluid made for transferring the heat to the outer casing. Would be really helpful for modding geared motors and provide a decent bit of information for people really wanting to push geared motors like myself. Also would love a more technical side to this if we get another video on what kind of power your fully pushing through the G062.

[@ElectricBikeLaboratory]

Excellent points. We did some hard pulls up and down the street for about 15 minutes and the motor got warm but not hot, right now its pretty cold to ride. Would love to push it in the hot summer and see if it survives. The phase wires unmodified may be the death of it but we figured upping the voltage should help. We will see! Might have to weld shut that keyway too.

[@Goesriding]

Why didn't you guys swap out the plastic gears for metal ones? Stripped gears gonna be a pain? The cooling liquid is ment to be in the center of the motor?, if it gets out into the gearing part how will it get back in?

[@ElectricBikeLaboratory]

We'll see if we can get the gears to strip, then we'll swap em out ;) ATF fills the air gap from rotor to outer shell with a liquid medium for enhanced heat transfer, the centrifugal force will always force the fluid to the outside, and provides enough to fill the air gap but not too much to increase resistance too much. At least that's the theory! We just wanted to try it, so far so good

[@pauly51]

I love this content. I’m 2yrs into my first e-bike purchase and now I’m interested in builds. Frankenstein models. lol.

[@ElectricBikeLaboratory]

Amazing! Thanks for following along! :)

[@kevinduprey9326]

Great skills!! Question.. on the engwe x26, it has 2 batteries but only 1 used at time. Could I combine the two and upgrade controller for higher output? How about adding additional mid drive motor? Looking for boost on hills. Would love to replace hub motor but I can't find upgraded hub motors with 26in mag wheel style.. only see spoke. Thanks

[@ElectricBikeLaboratory]

Thank you! On that particular bike you COULD run both batteries together with a parallel module (search "battery blender" or "parallel module). Then you have both batteries running together, and then you could tap into the battery line (Y splitter) and run a mid drive off of it for some serious hill climbing power :) Mag wheels are a lot harder to find than spoke wheels! Hope this helps!

[@suzannebooth6394]

Great mods will be watching for the next video on performance results !!!!!

[@ElectricBikeLaboratory]

Thank you! Stay tuned :)

[@msage002]

For a bbs02 build, would this 50e 13s3p config shown still be good config or would 13s4p make more sense because of the 25a draw of the motor? worried about longevity. thanks for the video!

[@TravisSelfmade-w8t]

Scuff it good and use jb weld , instead of thread gunk. Thats what i call it because it dont lock it tight it just keps it from backing out once it does break loose. So one day if you check your hardware and see some are loose but they are all still there ,then you torque them down better this time and your good instead of not having anything to retighten because they are absent

[@fhess400]

Start my 1st motor controls class In a week and a half. Thanks for all the helpful information. Anyway I can support your channel I will man. Thanks again

[@ElectricBikeLaboratory]

Thank you so much! Enjoy your class :)

[@TravisSelfmade-w8t]

Finger tighten your rtv surface until its dry then tourque it down in criss cross pattern but its not good to torque it when its wet becuse as it dries it shrinks and then after a season of temerature change it shrinks again . So if it dries finger tight then your accomodating for the shrinking and it will be good until its taken apart again

[@dg9bfc]

what about replace the plastic gears to metal gears?? i have seen a yt video of a guy replace the gears (cause worn out)

[@TheHappyDIYGuy-ri8nb]

Hi, this is a fail, you did not give a ride video at the end. It's like telling a joke without the punch line, get a clue man.

[@tommygreist9560]

Amazing build.....I've learned a lot❤.

[@AnthonySmith-k8v]

Does any one know Where the part 3 is for this mod?? I want to know what the outcome is.

[@crisostomos.ibarra]

You didn't post this on the road.. Why?

[@joesanner5581]

I love where you’re heads are at! I’m looking for someone to do some mods for me .

[@boodgiek8146]

What do you need peddles for ,whose going to peddle a 55 to 70 pound E bike when most regular bikes are 30to 35 pounds.

[@ElectricBikeLaboratory]

That's a great point!

[@MegaSloth]

Can I send my batteries to you guys to get this service done?

[@Funermen]

Really nice seeing how you did the modifications. Hope we get more videos on the g062 in the future.

[@ElectricBikeLaboratory]

Thanks, G062 is a pretty sweet little motor!

[@gregmcdermott8838]

Cool video keep up the good work all the way from Ireland 🇮🇪 👍

[@ElectricBikeLaboratory]

Thank you so much !! 🙏😊

[@Shartmiester]

Top speed?

[@johnconnor6725]

Easy, triple the voltage. My diy disability scooter goes 37 mph and that's on a 12" front wheel so it is very scary.

[@ElectricBikeLaboratory]

That's how you do it !! Just make sure you stay safe 😁👌

[@Funermen]

So few notes. I would suggest Shinko 244 over the 241 for the better center contact point or if your riding only roads then Shinko 567s would be even better for rolling resistance, I'm wondering if it might be better to weld the keyway right to the axle (not to the clutch) that way to get get rid of the worry of back and forth play over time in the keyway via regen while still being able to change the gears when needed.

[@ElectricBikeLaboratory]

Excellent points! I'm so used todefaulting to the 244 because we've used them on so many builds but yes there are some really good options out there

[@Funermen]

@@ElectricBikeLaboratory This is how I have categorized shinkos. 241 is 75% dirt 25% road 244 is a 50/50 dirt and road 567 is 0% dirt and 100% road

[@ElectricBikeLaboratory]

Those 567s look nice , probably should have went for those lol

[@marknowak6683]

Another powerful E-bike, oh boy! I was planning on buying an E-bike this spring. With the news awash with E-bikes being banned in more and more places, I think I will pass.

[@ElectricBikeLaboratory]

Hopefully they don't! Millions of people are using them now. UL listed batteries makes sense though

[@alexanderwoolley1623]

​@@ElectricBikeLaboratoryand in cases like mine I've found that firstly police don't enforce or choose not to enforce ebike laws so long as someone is using it responsibly, and secondly there's simply no way of regulating ebikes! With how often people build their own and mod them and upgrade components and drivers and batteries, it simply is not something that can just be "banned" and that people will actually follow! Think back to prohibition era America for example! :)

[@ElectricBikeLaboratory]

@@alexanderwoolley1623 Totally agree!!

[@stevepeacock1287]

You’re having way to much fun!

[@ElectricBikeLaboratory]

Yes, yes we are :P

[@paulmryglod4802]

Niiiiice

[@artofdisguy3401]

Cool upgrade

[@ElectricBikeLaboratory]

Thank you! :D

[@Madaz]

that looks awesome, how many watt is the orriginal motor 250w or 500w... ty

[@ElectricBikeLaboratory]

750W motor originally 😊👌

[@benedictarnold2648]

Hey myles, a point on the backlash/loose keyway problem: keyways are machined to press fit tolerances with a spec for surface area compared to shaft diameter. Any machinist handbook will have these industry standards. I would suggest getting hardened keystock with exact dimensions that comply with this rule of thumb(from my memory roughly 1/3rd of shaft diameter, the keyways are half of the keystock size) Another common practice is using set screws(this is where the locktite comes in) but this is usually only when the cog or bearing has room to walk off the shaft. Here its all held in the case so you wont have that issue. Cheers hope this helps Edit: could also be the heat from the weld youre contending with warping. Could try welding the keyway into the clutch with the stitch welds. Checking dimensions before and after

[@ElectricBikeLaboratory]

This is excellent advice, thank you!!

[@brendonfriesen8327]

This was a fun watch! So just to clarify. You put 16x3” tires on 20x4” fat bike rims? Is the lip on the fat bike rim smaller?

[@ElectricBikeLaboratory]

Hey there thank you! Bicycle tires are referenced by the tires outer diameter and motorcycle rims are referenced by the rim diameter , 16in motorcycle wheels happen to fit 20in bicycle wheels they basically match in diameter , the 3.0 stretched to about 3.5in when mounted on the rim and inflated 👌thanks for the comment !!

[@sterlingtmeyer]

Nice work gentlemen

[@mikerocket62]

how much did labor and parts cost? Great job BTW!!!

[@ElectricBikeLaboratory]

Controller was $300 we did the labor , battery cost around $200 to build ;) not too expensive

[@georgekrpan3181]

SUBSCRIBED! Wow, I had wondered if it were possible to up the voltage to 72v by adding a 24v battery. So, the 750w Bafang motor will survive at 3000w? I have a Troxus Explorer. I replaced the 26x4 knobbies with 26x3 Duro Beach Bum slicks. These tires are motorcycle-like in their toughness, no flats and hardly any wear after 1800 miles. I'm skeptical about regen. The charge rate of batteries is so low that I doubt how much regen helps, and, I prefer throttling the bike with the pedals. The Explorer is a great pedaler.

[@ElectricBikeLaboratory]

The skepticism about regen is very warranted, it is a really fun feature though. But yes, you can't put too much back or its pretty easy to trip the BMS overcharge current. We've seen people online push the Bafang G062 to 7000W before failure, they are pretty dang robust! 26x3 Duro beach bum slicks must be a nice upgrade. Thank you so much for the comment! :D

[@georgekrpan3181]

@@ElectricBikeLaboratory Thanks so much for your reply. I guess I'm going to have to investigate hopping up my G062. According to the display the peak power is almost 1000w. If I could just tweak it to 2000w I'd be super happy. I wouldn't run it at 2000w all the time but it would be fun to be able to. Cheers!

[@ElectricBikeLaboratory]

2000W is a good amount of power 😉

[@georgekrpan3181]

@@ElectricBikeLaboratory Yep!

[@christianwhite1771]

Is that bafang motor

[@ElectricBikeLaboratory]

Yes it is Bafang G062