Hardcase mounting system
With 100 cells (5P 20S) the pack is big (it needs to be). We like going fast on bikes, but we also like handling performance and the feeling like we're still on a light weight bicycle. The Hardcase was designed by Dillenger specifically for this kit and this battery pack. We didn't believe a loose, soft battery bag was a good option for an electric bike travelling at 40mph off road. We've grown tired of riding our own bikes with a pile or RC lipo bouncing around like a bag of bricks wondering which landing is going to do damage. The Hardcase mounting system combines all the conveniences of the very popular styles of 36V and 48V mounting systems (such as compatibility and practicality) with the huge capacity of high drain cells required for a 72V 90A discharge (3,600W peak). The Hardcase mounts easily to your down tube, with a controller mounting plate and also allows the battery to be removed without taking apart the mounting system.
The limitations on performance to date are essentially in 3 main points. Battery drain, battery voltage and battery size. The technology for fast motors and controllers has existed for long enough, it's the battery system that has been the limiting factor. Normal 18650's die prematurely if you regularly draw high currents. A high drain cell such as those used in this battery are designed to be have a 20A draw without dying prematurely. Battery voltage is a limiting factor for both power and speed. You don't really get much more than 50km/h and 2,000W from a 48V system. The only 72V battery packs are either huge bricks, soft bags or RC lipo packs, all of which we wouldn't offer as a conversion kit power pack. Battery size is an issue of practicality. Lipo's are not a safe option for consumer electric bike products. So to mount 100 18650's within a bike frame in a rigid, removable and stealth case was the challenge. The Hardcase achieves this task and keeps the weight of the pack in a location that doesn't destroy the bikes handling performance.
With motorcycle-like power safety is a major consideration. The wheels are professionally built by crystaylte who have the most experience of anyone in the industry when it comes to powerful hub motors. The battery features the same safeties and redundancies as our 36V and 48V batteries. The safety and reliability of 18650's make this option the safest available to us. The battery pack is protected by the Hardcase system which prevents any intrusion or blunt force damage. The Hardcase system mounts the pack and controller securely to the strongest part of the bike. Also key to safety is keeping the motor in the bike. If you've experimented with powerful Mega torque arms
Most powerful kit available, why hub motor?
Unless you're converting a motorbike to electric, there are limitations on what a mid drive system will deliver. Yes, they are one of the best kits available (BBS-HD) and super reliable. But it's still a bicycle. Once you go over 1,600W peak, you're going to break chains like rubber bands. If you're going to change the chain wheel, chain, rear sprocket, hub, wheel, rim, tire, chain stay and drop out clearance - you might as well convert a motorbike. If however you're looking at building a custom, high-powered bicycle, hub motor is the ideal option. Hub motor drive does not involve much of your bike. The major issue with high powered hubs (and any hub motor with torque) is dropout integrity. That's why we developed the 'Mega torque arms' which largely remove the risk of drop out failure.
|Designation||High powered conversion kit|
|Main Use||Custom e-bike builds|
|Max Speed||65km/h (40mph)|
|Throttle Type||Twist throttle|
|Battery Chemistry||LiMn2O4 Lithium Ion|
|Nominal Battery Voltage||72V|
|Charged Battery Voltage||84V|
|Nominal Battery Energy||900Wh|
|Battery Cell Type||18650|
|Cell Spec||LG18650HE2 (20A)|
|Built in BMS||Yes|
|Other Features||Secure, armored Hardcase protection|
|Maximum Battery Charge Cycles||1,000 design life|
|Battery Charger Type||3A Charger|
|Battery Charge Time||4 hours|
|Motor Model||TC4065 (138mm dropout clearance)|
|Motor Voltage||72V 65km/h winding|
|Max Motor Power||Limited to 3,600W by controller|
|Drive Type||Direct drive|
|Motor Sensors||Hall sensor feedback to CA|
|Controller Operating Voltage||72V|
|Controller Operating Amps||90A|
|Controller Nominal Power Output||3,600W|
|Controller MOSFET Tubes||4110|