Chaos - 2007

Part 3


Having 15 lbs on the rear rack and the other pack on the downtube improved the handling.

The next upgrade was the "Backlit Drain Brain " . The " DB " as it was called at the time, now the " Cycle Analyst " a product created by an engineer from Vancouver BC, no electric bike nut should ever be without one, i have this meter on all my ebikes.

This meter has a wire and " shunt " that connectes between your battery pack and controller, it monitors how much power you have consumed, how far and fast you are going, displays pack voltage, and keeps track of your total kms/cycles/etc..

At the time i received it, the DB was still going thru alot of changes and updates, and I had to replace a small resistor inside for the backlight to function at 72v.


Yes, that right there is a very .. very... small resistor, soldering one in is no easy task.. but with a bit of courage i managed to get that done and it worked !.. phew.

So now i can ride at night and have a nice blue glowing display.


I drove this version of the Chaos for a few months, alot of kms, everything held on like a champ.

During this time, i started experimenting with Lithium batteries

Above is a picture of my 1st test ride with 2 x 36v 20ah Lithium Manganese packs in my backpack... I came back from this trip with what has been described as the " EV-Grin "... :-)

An electric motor will spin faster with higher voltage, so more volts = More RPM .

72v Nimh was giving me 84v hot off the charger, then dropped to 70v right away and kept dropping down to 60v gradually during the ride if drained completely.. this gave me a speed of 37 km/h in 409 mode.. and 50 km/h in 406 mode. Range = 40 kms per charge if taking it slowly.

72v Lithium was giving me 84v hot off the charger, but 80v for a good 10 kms.. then 80v down to 75v for another 40 kms and kept going and going.... 409 = 40 to 42 km/h.. and 406= 65 km/h + !!!!!!!!!! Range = 80 kms per charge ! without pedaling if you cruise slowly at 30 km/h without fighting too much wind !

Shortly after..

Came home one night after work, 10 ft from my driveway, i heard a SNAP.. and that's right.. broken rear rack... ( not my first broken rack mind you.. and for what it went thru.. i'm amazed it lasted as long as it did !! )

So this was a sign, out with the Nimh.. in with the Lithium !


Above you can see the difference between 8ah Nimh and 20ah Lithium, both 36v. The lithium pack is larger in size, but comparable in weight to the Nimh pack.. it's like holding a cement brick and a piece of wood the same size, very deceiving.

Considering that the lithium pack has 20 amp/hour of capacity, and can deliver more amps than the Nimh pack without getting hot, it makes for a world of difference on a serious commuter bike.

Once again, how do you bolt 30 lbs of batteries to a bicycle frame without breaking stuff...?

You double the support!


Unlike the Nimh , i wanted the batteries to be visible, considering the 1500$ price tag on these packs.. scavenged a piece of Macrolon lexan polycarbonate, un-breakable, non-conductive, and bendable..

Using clamps, a few pieces of angle iron and a heat gun, carefully heat the edge of the sheet at the angle iron line and once it softens up you bend it and hold while it cools down.. too much heat and it melts in a bubbly mess, but not enough and it's almost impossible to bend... took a few tests but i managed to get it down after a while.


Using 2 part epoxy glue and clamps, the 2 sections of the boxes were sealed together, and the caps were doubled up for thickness and support, I painted the inside of the end caps black to match the bike..

Cut some 3" wide strips of Stainless Steel, 16 gauge, to wrap both packs onto the rear rack..

Had to buy a drill press in order to drill thru the Stainless, this stuff is HARD.. and i was destroying drill bits with a hand drill. A man never has too many tools.. so having a press makes alot of other projects easier.. well worth the investment.





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