TQFreak's Dengfu E55 Build Thread

[TQFreak]

I ordered an empty battery case on aliexpress, still waiting for the frame to be shipped but dengfu has delays...

View attachment 107401

I partially disassembled the battery supplied with the frame. Here is the process

The charge level indicator connected to BMS with 4 wires. I'm wondering if it is possible to replicate this functionality with different BMS for custom build battery?

They use something like white color silicone glue or maybe soft potting compound to secure the wires and the battery pack. The battery pack is protected with a few foam pads from contacting with the aluminum extrusion tube and glued with the same white rubbery stuff in the aluminum extrusion tube so I decided to not pull it out to keep it secured with the glue.

 

[TQFreak]

You're right. If not then I can somehow have one fabricated for me.

Could you please also make one photo of the inside of the downtube. I want to understan if there the same 2 bolts that hold brackets securing all the housing.

Thanks!

Here is the part number for the plastic cover (Reention PLA0561). Maybe it will help you to find it.

Here are the close pictures from the inside of the frame downtube

Bottom of the downtube view from the motor area

Bottom of the downtube view from the battery area zoomed out

Bottom of the downtube view from the battery area zoomed in

Top of the downtube view from outside

Top of the downtube view from inside zoomed out

Top of the downtube view from inside zoomed in

 

[TQFreak]

OK, I just printed the Kindernay shifter torque arm out of polycarbonate on an FDM 3D printer and it fits and works without issues. So if you are going to install Kindernay gear hub on Dengfu frame you can 3D print this part and fix the shifter housing with it. I would recommend you to use polycarbonate or PETG filament.

Here is the link to downaload the 3D file of the Kindernay shifter torque arm


You also are going to need a stainless steel M5x16mm screw

McMaster-Carr

McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.

www.mcmaster.com

and a a stainless steel M5x10mm OD washer

McMaster-Carr

McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.

www.mcmaster.com

Apply Loctite blue and install it

 

[TeoElFeo]

Thank you for the detailed photos, they have been very informative!

Would it also be possible to measure the distance from the rear(motor) wall of the downtube until the ridge that is in the upper part of the tube. Basically trying to figure out how much flat space is there available for calculating custom batterypack size.

 

[TQFreak]

Here is some information about the Innotrace X2 display for the Innotrace X1 controller can be helpful.

The Innotrace X2 display advanced settings are locked by a password. The advanced settings allow you to set the correct wheel diameter and pedal assist speed limit.

Innotrace still did not respond me about how I can reach those settings but I figured out it myself after sore research.

Here is Innotrace X1 (Eggrider) display manual, it has some similarities to Innotrace X2 display (Intelligent OLED Display DM03) and finctions

https://acts6-my.sharepoint.com/personal/r_czernig_inno-trace_de/_layouts/15/onedrive.aspx?id=%2Fpersonal%2Fr_czernig_inno-trace_de%2FDocuments%2FAnleitung%20X1%20Display%20Englisch&ga=1

Here is the Innotrace X2 (Intelligent OLED Display DM03) display manual from the OEM manufacturer

https://cdn.shopify.com/s/files/1/0588/1125/2889/files/varstrom_dm03_display_user_manual_en.pdf?v=1661845940

To enter the display settings menu on Innotrace X2 display you have to turn the display ON and then press and hold the "M" button withing first 10 seconds after the display is turned ON.

Then you go to the "ADWSet"

Set the password 1657

And now you are in the Advanced Settings menu

Set your wheel diameter

Set your pedal assist speed limit

And here are all the advanced settings password combinations I found in the internet for Dengfu motor powered bike displays you can try in case the one I posted will not work for you so maybe you don't need to try 10000 combinations to find the one

1657
1919
1199
1801
0512
0486
0000

 

[TQFreak]

Thank you for the detailed photos, they have been very informative!

Would it also be possible to measure the distance from the rear(motor) wall of the downtube until the ridge that is in the upper part of the tube. Basically trying to figure out how much flat space is there available for calculating custom batterypack size.

Here are the sizes. The distance between the ribs is 483mm. The opening length is 435mm. The distance between the bottom edge of the opening and the rib at the motor compartment is 24mm

Also pay attention the upper rib goes not straight vertical along the whole height, it makes turn, but that turning portion in opened up. The open portion of the rib which does not go straight vertical is about 71 mm. If you can squeeze the battery in this space you can probably ignore this rib turn

 

[TeoElFeo]

Thank you for taking the time and giving those measures! Perhaps I didn't clearly explain which part I meant so I will try again.

I wanted to ask about the distance between the inner side of the motor rib and the very begining of the upper rib.

In fact I think the battery shape will follow the upper rib so I am trying to figure out how many rows of batteries I can fit before having to make the odd shape placement. Also what is the inner width of the downtube?

 

[TQFreak]

Thank you for taking the time and giving those measures! Perhaps I didn't clearly explain which part I meant so I will try again.

I wanted to ask about the distance between the inner side of the motor rib and the very begining of the upper rib.

In fact I think the battery shape will follow the upper rib so I am trying to figure out how many rows of batteries I can fit before having to make the odd shape placement. Also what is the inner width of the downtube?

If you will be able to squeeze the battery somehow through the lower rib opening to the motor it will add 19mm. Here is the distance between the lower rib to the motor. So you will have 483mm+19mm=502mm between the motor and the upper rib.

The inner section of the downtube is 115mm x 84mm. There is also a couple of glued bottle mount inserts protrude 10 mm inside the internal space of the downtube

The odd shape upper rib is about 45mm wide if measured along the downtube length

 

[TeoElFeo]

Thank you so much! Now I have all the measurements needed.
Also wanted to ask if the grey cylinder in between bottle cage mounts is a threaded mount for cable routing bracket?

 

[TQFreak]

Thank you so much! Now I have all the measurements needed.
Also wanted to ask if the grey cylinder in between bottle cage mounts is a threaded mount for cable routing bracket?

There are two grey cylindrical threated mounts for the two aluminum brackets supplied with the frame for cables routing. They occupy about the same 10mm height with attached aluminum bracket as the brown bottle mounts threated cylinders.

 

[TeoElFeo]

Perfect. I was planning to use them to attach straps to the frame that will hold my custom battery.

In theory I should be able to fit 48v 30ah battery. In practice I will find that out in a couple of months once I get the frame

 

[TQFreak]

Kindernay VII shifter hoses are not long enough, so I purchased 10 meters of 2.0*5.0mm hydraulic hose

In order to have access to the swingarm cables holes I detached the lower mound of the swingarm.

The holes for the cables in the swingarm allow to route only one cable. Kindernay shifter requires two hoses. So I enlarged the right cable opening with Dremel

Then I enlarged the original hole

And drilled another hole for second hose near the first one starting from small drill bits and following ladger drill bits

So now I have two holes large enough to route two hoses through the swingarm

Cleaned the carbon dust with vacuum cleaner

Pushed 2 hoses through the swingarm and picked them from the swingarm opening

Cut both hoses with extra length from the main spool

 

[TQFreak]

The nest thing I did is I routed the Magura MT5t brake hose through the left side of the swingarm.


Attached the brake lever to the handlebar so the hose goes up

Clipped the brake hose off at the brake lever

Plugged the hose with the plug supplied with the Magura brake kit

Clipped off the plug head so it will not interfere with the mall channel in the swingarm

Attached the cable frame grommet supplied with the frame to the hose

Routed the brake hose through the left side of the swingarm

Routed the Kindernay and the brake hoses through the brame and hanged the brake hose at the high point so it will not leak with oil

Clipped the hose grommet to the place

Attached the swingarm back

Attached the rear brake caliper

Then I cut about 200mm of flexible plastic tube (4mm inside diameter, 6mm outside diameter) and cut at along the length

And attached it to the brake hose where it goes between the swingarm and the frame to protect it from rubbing on the frame

Secured it with electrical tape

Attached the magnet sensor supplied with the Innotrace X1 motor

Routed it into the frame

Secured it with zipties

Installed the magnet sensor rubber cover supplied with the frame

Detached the rear brake from the handlebar keeping the tube faced up and placed the frame on side to proceed with cables routing

Attached the brake hose open end to the highest point so it will not leak

Routed the dropper post cable housing supplied with the dropper post PNW PUGET MTB LEVER Puget 2x Lever

Attached the bushing to the cable

Attached the cable housing cap to the cable housing on the dropper post end

Routed the cable though the housing

Routed the motor harness

Attached the fork and handlebar

Put the frame in upright position, attached the brake lever to the handlebar and marked the rear brake cable cut place making sure the brake cable has enough slack inside the frame to make turn in the frame steering head and around the battery upper mount

Removed the brake hose shroud from the brake lever and attached it on the hose

Detached the nut from the brake and attached it on the hose

Attached the olive supplied with the brake kit to the hose

Trimmed the hose

Attached the hose insert supplied with the brake

Detached the original hose end from the brake lever and discarded it

Attached the trimmed hose to the brake lever

 

[TQFreak]

The Bafang m620 wiring harness supplied with Innotrace X1 motor has yellow 3 pins connectors for brakes e-stops but those connectors are incompatible with Magura MT5e brake connectors (2 pins).

You can make them compatible using this method






But I decided to purchase another Bafang m620 harness with Magura MT5e connectors

Magura Main Wiring Harness for Ultra M620 G510

This e-bus cable is the main wiring harness which extends from the motor to the handlebars and allows you to connect throttle, brakes and display. This Ultra Special E-bus Cable features two Higo 2 conductors (Red) plugs when connecting the Ebrake cutoffs. This combination is very superior to...

california-ebike.com

Unfortunately this cable is shorted than the original Bafang m620 harness and it is too short to fit Dengfu e55 17" frame

So I decided to use these two cable to make one long cable with Magura MT5e connectors

I cut a piece on the motor side from the original harness long enough

Removed part of the main insulation

Cut off the plug from the Bafang m620 MT5e cable

Trimmed the wires with matching colors to the stepped lengths (to prevent growing thickness of the cable and possible shortage)

Stripped and tinned the wires

Attached the harness sleeve to the motor plug exposed wires area to protect the exposed wires and to keep them flexible at the same time

Secured it with heat shrink tubes with adhesive liner

Attached the heat shrink tubes with adhesive liner to the cable and to the wires

Soldered the wires with corrsponding colors and leghts

Fused the heat shrink tubes

 

[TQFreak]

To figure out where to trim the dropper post cable I attached the Kindernay Onesie shifter to the handlebar to the position where it supposed to be, attached the the dropper post with attached dropper post cable, attached the dropper post lever where it supposed to be, maintained proper slack of the dropper post cable inside the frame so it goes in the steering tube and round the battery upper mount without interference and marked the cable trim line

Removed the dropper post and the cable from the cable housing and trimmed the cable housing

Attached the cable to the cable housing

Connected the cable to the dropper post and attached the dropper post to the frame

Attached the lever housing cap to the lever side of the cable

Attached the cable guide

Attached the cable to the lever

 

[eugene8]

A sheath for shifter has metal housing inside to prevent abrasion. The hydraulic one is made of plastic. Better find a dedicated shifter sheath for it to live a long happy life ))

 

[BojanZ]

Here is some information about the Innotrace X2 display for the Innotrace X1 controller can be helpful.

The Innotrace X2 display advanced settings are locked by a password. The advanced settings allow you to set the correct wheel diameter and pedal assist speed limit.

Innotrace still did not respond me about how I can reach those settings but I figured out it myself after sore research.

Here is Innotrace X1 (Eggrider) display manual, it has some similarities to Innotrace X2 display (Intelligent OLED Display DM03) and finctions

https://acts6-my.sharepoint.com/personal/r_czernig_inno-trace_de/_layouts/15/onedrive.aspx?id=%2Fpersonal%2Fr_czernig_inno-trace_de%2FDocuments%2FAnleitung%20X1%20Display%20Englisch&ga=1

Here is the Innotrace X2 (Intelligent OLED Display DM03) display manual from the OEM manufacturer

https://cdn.shopify.com/s/files/1/0588/1125/2889/files/varstrom_dm03_display_user_manual_en.pdf?v=1661845940

To enter the display settings menu on Innotrace X2 display you have to turn the display ON and then press and hold the "M" button withing first 10 seconds after the display is turned ON.

Then you go to the "ADWSet"

Set the password 1657

And now you are in the Advanced Settings menu

Set your wheel diameter

Set your pedal assist speed limit

And here are all the advanced settings password combinations I found in the internet for Dengfu motor powered bike displays you can try in case the one I posted will not work for you so maybe you don't need to try 10000 combinations to find the one

1657
1919
1199
1801
0512
0486
0000

Man, I have to try these paswords, thanks! I also have the same stuff from innotrance as you, unfortunately their responses are very bad and still got no answer from them about this password, even though I emailed them at least three times how to change wheel diameter!! Btw, my stickers on the motor are the same as yours. Have it on E22 frame and set it to 40A max current.

 

[rezystor1990]

If it's not a problem, you can measure the length:
- the length of the rear brake cable
- the length of the Kindernay cable
- the length of the line to the adjustable seatpost

My frame is still in China I currently have a M620 with a seroxat frame, I will be transferring all the equipment to the new frame. If I had the dimensions, I would check if my cables are long enough or do I need to buy new ones.

 

[TQFreak]

I can not measure exact length of those cables - they are already installed on the frame. I can give you rough length when I will have time to measure it but I would not trust those numbers if you are planning to use it to trim your cables.

 

[TQFreak]

If it's not a problem, you can measure the length:
- the length of the rear brake cable
- the length of the Kindernay cable
- the length of the line to the adjustable seatpost

My frame is still in China I currently have a M620 with a seroxat frame, I will be transferring all the equipment to the new frame. If I had the dimensions, I would check if my cables are long enough or do I need to buy new ones.

OK, I did rough measurements:

Rear brake hose length is about 2000mm

Kindernay each hose length is about 2000mm

Post dropper cable length is about 1670mm

Front brake hose length is about 1000mm

Again, do not trim the hoses and the cables to this lengths, this is rough data I measured without detaching the cables from the frame.

 

[TQFreak]

For the wheels rims I purchased a couple of Nextie [Jungle Fox II] 29" MTB Rim 52mm with 32 holes

[NXT29JF52-II] [Jungle Fox II] 52mm Width Carbon Semi-Fat MTB 29+ Rim Hookless Tubeless Compatible 29-52mm | 34mm Depth | 530g | Tubeless | Tire 3.0~3.8" | AM / Enduro | 3.5mm Rim Lip Thickness

[NXT29JF52-II] [Jungle Fox II] 52mm Width Carbon Semi-Fat MTB 29+ Rim Hookless Tubeless Compatible 29-52mm | 34mm Depth | 530g | Tubeless | Tire 3.0~3.8" | AM / Enduro | 3.5mm Rim Lip Thickness

www.nextie.com

The front hub is SRAM 900 Front Hub - 15 x 110mm Boost, 32H, 6-Bolt, Black from eBay

SRAM 900 Front Hub 32H 6-Bolt Disc Black 15x110mm Boost Compatible A1 | eBay

SRAM 900 Front Hub 32H 6-Bolt Disc Black 15x110mm Boost Compatible A1

www.ebay.com

The spokes are custom cut 2mm black SAPIM spokes from eBay

16 spokes 276mm long for front wheel brake side 3 cross pattern
16 spokes 279mm long front wheel non-brake side 3 cross pattern
32 spokes 253mm long for rear wheel Kindernay 32H SWAP Shell both sides 2 cross pattern

Custom length 14g (2.0mm) BLACK Stainless J-bend bicycle spokes - No nipples | eBay

NO NIPPLES. I prepare my high quality spokes on Phil Wood spoke machines. The Phil Wood machines will cut to precise lengths, and then will cold forge roll threads. (I won't do it) Sorry to sound sound rude but I just want to throw it out there so it's no surprise.

www.ebay.com

Nipples are DT Swiss Brass Nipple 2.0mm

Spokes threat locker is Wheelsmith Mini Spoke Prep, 15ml - Blue

Both tubes are MAXXIS Welterweight Tube 29x2.0-3.0 PV 48mm 0d


Both tires are WTB Ranger 3.0 x 29 TCS Light/Fast Rolling 60tpi Dual DNA SG2 tire

Rim tape is WHISKY - Tubeless Rim Tape - 45 mm Wide, 10 m Long

Reflectors are Labewin

https://www.amazon.com/dp/B077YJT2LY?psc=1&ref=ppx_yo2ov_dt_b_product_details

Cleaned the spokes

Applied the threat locker

Lubed the nipples to rim contact surface

Laced the front wheel

Trued the wheel on the fork with a piece of cardboard and a couple of zip ties

Set spokes tension around 100-120 kgf

Cleaned the rim internal surface with alcohol and applies two layers of the rim tape

Cut the hole for the inflation nipple

Attached the tire and the tube

Inflated to around 35 psi to seat the tire bead and dilated to 25 psi

Attached the brake disk

Attached the wheel reflector

Attached the spoke reflector

 

[TQFreak]

And here is the front wheel

Then I laced the rear wheel

Trued it on the bike swingarm with a piece of cardboard and a couple of zip ties

Applied two layers of the rim tape

Attached the Kindernay VII gear hub to the wheel

Attached the brake rotor spacer and the brake rotor

Attached the torque arm with the spacer cup

Attached the cog

Attached the reflectors, attached the tire and the tube, seated the tire bead with pump and deflated the tire (It is not possible to attach this rear wheel to the Dengfu E55 with inflated tire, it needs more room to reach the rear hub slots in the swingarm).

Attached the deflated wheel to the swingarm

Inflated it

This rear wheel maintains about 1 mm gap with the mud cover rubber when it is inflated to 25 psi

Attached the speed sensor magnet

 

[TeoElFeo]

I would say that 1mm gap is far from ideal... Things flex in the rear triangle a bit and mud and some debri can get stuck between the tire and frame. Also if the wheel good out of true it might start rubbing on the sides. Why such a peculiar choice of tyres? To me 29x2.6 seems plenty

 

[TQFreak]

I want to fit the widest tires possible because of they look better and performs better on sand and snow.

Sneak pick. This 52V 3000W Innotrace motor combined with 46T chainring, 14T cog, Kindernay VII at highest gear (2.068 gear ratio) and 29" wheel is able to spin the wheel over 70mph (110kmh) with the throttle

 

[TeoElFeo]

Looks nice! In reality I doubt that 3kw motor will allow you to get to that speed simply due to rolling and air resistance. Nonetheless it will be a very fast bike. Did the 46t chainring come stock with the Innotrace?

I have ordered my frame already and I am planning to go Innotrace with the motor.

 

[TQFreak]

No, the Innotrace went with 44T steel chainring. By the way 44T chainring will interfere with the swingarm if mounted on the internal face of the spider. It looks like 42T chainring is the biggest chainring can be mounted on the internal face of the spider without interfering with the swingarm. The external face of the spider allows to mount 46T chainring maximum without touching the swingarm.

I purchased an aluminum 46T chainring with integrated guard and mounted it on the external face of the spider.

 

[Bengy22]

Bike is looking awesome! Those tires are huge, and the kindernay is looking sweet, loving the huge detailed write up you are going for the build. And looks like you are getting close to doing a test ride which sound be fun to hear about!

 

[TeoElFeo]

No, the Innotrace went with 44T steel chainring. By the way 44T chainring will interfere with the swingarm if mounted on the internal face of the spider. It looks like 42T chainring is the biggest chainring can be mounted on the internal face of the spider without interfering with the swingarm. The external face of the spider allows to mount 46T chainring maximum without touching the swingarm.

I purchased an aluminum 46T chainring with integrated guard and mounted it on the external face of the spider.

Looking at the spider I would say the chainring is meant to be mounted on the external side. How does the chain line look when mounted externally?

 

[TQFreak]

The chain line looks pretty straight.

 

[Dado]

Tqfreak, you are crazy!
Thanks for excelent photos. Your build must have taken hundreads of hours. Kudos to the stickers. And also to your craftmanship.

Anyway have also Inno and also very bad experience. That company is a joke.
Motor came also not setup as I ordered, X2 display does not work with their controller ( Rico did not want to refund). I had faulty torque sensor from factory! Where is some qc testing? And also faulty throttle. I had to buy programming cable (I think it is intention to ignore your setup then u need to buy programmer also)
I can share a setup, been experimenting a while.