Schwinn Electric 2Schwinn Electric 3Standard Battery ModuleStandard Battery ModuleStandard Battery ModuleModular Battery chargingModular Battery Checking
OwnerJohn Bidwell
Owner's Other EVsMountain Bike
1987 Kawasaki Ninja 750
2004 Kawasaki KX125
High Performance Motorbike
LocationFort Collins, Colorado United States map
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Vehicle2006 Schwinn Voyager SPT 29er Hybrid
Economical HUB conversion bicycle with crisp
performance from LIPO custom battery Modules
MotorCrystalyte 408 brushless 3-Phase AC
Relatively Light weight motor configured for top
speed not torque
DrivetrainModel 408 Crystalyte rear hub motor with 7 speed
Controller Grin Tech Infineon Chip Brushless
Small reliable BLDC Controller
72 Volts
26 Volt cutout
Batteries44.40 Volt, Lithium-Polymer
Bidwelldesign Custom battery modules
45 volts X 5 amphrs from 2 Turnigy 22.2 volt
batteries in series.
Turnigy batteries are packaged in a standard
plastic case (see photo). That Module is
removable from standard aluminum mounting

Battery modules can be quickly swapped with
fresh pack and/or easily removed for charging.
System Voltage45 Volts
Charger Thunder AC6
Uses 2 6S balancing chargers in parallel for
fast charging of a standard battery module
DC/DC Converter None
InstrumentationBicycle Odometer

LIPO Battery Monitor sees each cell voltage for
balancing connector
Top Speed24 MPH (38 KPH)
Bicycle gearing well matched for rider
contribution during cruising at top speed
AccelerationVery snappy with high amp LIPO battery modules
compared to the original NIMHD battery pack
Range12 Miles (19 Kilometers)
12 miles per standard battery module at 20 MPH
with moderate pedaling.

Carry a backup battery module or 2 and double or
triple your range to 24 miles or 36 miles
Watt Hours/Mile18 Wh/Mile
18 whr/mile at 20 MPH with some pedaling

23.5 whr/Mile at 24 MPH with some pedaling
EV Miles
Current:194 Miles (312 Kilometers)
    As of 5/31/2015
Seating Capacity1 adults
Curb Weight54 Pounds (24 Kilograms)
Includes one 4 LB battery Module.

Each additional battery module is 4 LBS.
Tires700 X 40C
Conversion CostMotor $293
Controller $200
Batteries $150 for two Turnigy 6S 5 amphr 40C
Bike $217
Misc $100
Additional FeaturesThe 4 LB Modular battery approach allows for carrying of extra
range extending modules in a backpack or saddle bags. These
modules are easily removed for charging or parking security.

This standard plastic 48 volt 5 amphr battery module is very
light(4 LB), low cost ~ $150 and also usable on other vehicles
(see Slick electric motorbike on EVALBUM).

The bicycle is nimble and easily navigates around town and is easy
to carry on bus systems or by car bike rack.

The motor is very smooth and quiet

The Throttle has a set of LEDs that tell battery charge.

Lipo battery Checker gives readout for every cell (useful for
checking cell balance which is important for LIPOs)
Bicycle purchased used from a friend (Tim Tillson) who put the
original conversion together using NIMHD batteries.

The NIMHD batteries(two 24 volt 13 amphr) were heavy, large, hard to
mount, and low power. They were however easy to charge and safe and
seem to have lasted.

I used the bicycle as a test bed for various battery mounting
approaches and finally came up with the Modular plastic box with two
standard LIPO batteries inside. This plastic moduule is easily
mounted and removable from an aluminum electronics project box with
one end removed.

code by jerry