BMC Alpenchallenge AMP with EP8 motor

[ultrajapa]

Hi everyone, first post so be gentle please.
I own two versions of Alpenchallenge AMP (carbon and aluminium)
I have changed motors on both to newer generation EP8 and bikes perform amazing.
The problem is with motor covers as they been designed to fit on older DU-E8000 and DU-6100 units.
I made some DIY prototypes using epoxy and heat gun but those aren't perfect.
They are glued on so any motor service requires ungluing and glueing back on.

I am looking for someone who has some knowledge or tips to help me design those covers for 3D prints.
Or point me in a direction to whoever is in a 3D design business.
The idea is to get them (new covers) fit with EP8 screw holes so they can be easily removable and serviceable.
Bottom motor covers used here are genuine Shimano products (DC-EP800)

Thanks
Bart

 

[itsmcgee]

Bart, I am also interested in securing a file to print. I am going to make the same upgrade to my ltd. If you get any help, please pass it on.

 

[ultrajapa]

Bart, I am also interested in securing a file to print. I am going to make the same upgrade to my ltd. If you get any help, please pass it on.

Hi.

Just few tips about EP8 upgrade.

Apart from few di2 cables and cable adapters you may consider also a new speed sensor that will connect directly into EP8 with new thin connector (EW-SS301).

Old sensor can be used but needs EW-AD305 adapter. Where I live price of this adapter with short EW-SD300 cable is comparable to new sensor - so better go with new sensor.



Also new crank arms are required. I used FC-M8150 but anything that is compatible with EP8 will do.

 

[itsmcgee]

Thanks very much for the added information. Did you notice a reduction in motor noise when you made the change? This is my big reason for the change. It seems much noisier than my other ebikes. The carbon LTD is a really fun bike to ride, but the noise level is not what I want,
.

 

[ultrajapa]

Thanks very much for the added information. Did you notice a reduction in motor noise when you made the change? This is my big reason for the change. It seems much noisier than my other ebikes. The carbon LTD is a really fun bike to ride, but the noise level is not what I want,
.

Of course both EP8 motors are much quieter compering to 6100 and 8000 versions.
I also notice that motor on a aluminium bike with a belt is whisper quiet vs just quiet on my carbon LTD bike.
Shimano is forcing some reduced power settings on EP8 if it is used with Di2 belt driven hubs - max torq is only 50Nm on the highest level of assistance (plenty enough for my needs)
No such a reduction happens when belt driven hub is mechanical (not Di2)

 

[ultrajapa]

Currently upgrading one of my BMC AMP bikes from EP8 to EP801....

It is completed now apart from motor covers.
Went for Di2 Rear Mech RD-M8150 combined with 11-36 12 speed cassette.
Switches on the handlebar are SW-EN600-L and SW-EN600-R
Motor has now unlocked assistance up to 50km/h thanks to Markus from eMax tunning.

 

[itsmcgee]

Nice job. Thanks for sharing. That was using the "pay for version" of the eMax? I've used the free version to modify the power output on my orbea mountian bike and it works great. Going to the 801 since you have to replace everything is quite spendy but seems to make you a great bike. I still have not converted mine as Shimano USA has the ep800 on backorder. They are projecting October delivery.

 

[ultrajapa]

Nice job. Thanks for sharing. That was using the "pay for version" of the eMax? I've used the free version to modify the power output on my orbea mountian bike and it works great. Going to the 801 since you have to replace everything is quite spendy but seems to make you a great bike. I still have not converted mine as Shimano USA has the ep800 on backorder. They are projecting October deliver

It was using paid version of eMax.

I got lucky and managed to source brand new EP801 motor with zero miles done from eBay Germany for only €350

Currently modeling and sanding another motor cover that should look and fit much better when finished.

 

[itsmcgee]

That's looking good. Is that a combination of the shimano cover and the bmc cover spliced together. I'm going to have to come with a cover also, as I haven't found anyone to make a file I could print. I really appreciate you sharing your info. My local dealer says shimano is now looking at a late october delivery for the EP800. My patience is really thin. I am looking at alternative places to shop.

 

[ultrajapa]

That's looking good. Is that a combination of the shimano cover and the bmc cover spliced together. I'm going to have to come with a cover also, as I haven't found anyone to make a file I could print. I really appreciate you sharing your info. My local dealer says shimano is now looking at a late october delivery for the EP800. My patience is really thin. I am looking at alternative places to shop.

That's a long wait.... I would probably have another 1000 ideas of other bikes by then.

Managed to finish cover just now and painted it in Satin black finish.
This time it won't be glued on as it has two mounting points for bolts so motor and all connector points will be fully serviceble.
The base for this cover was originally BMC cover for DU-E8000 motor that was used on Alpenchallenge LTD models (search BMC motor cover kit 301669)
It was cut in several places and bend with heat gun. After that I used epoxy putty to file gaps and sand paper to finish.
Shimano DC-EP801 cover is used at the bottom.

 

[itsmcgee]

Well, I got tired of waiting and ordered an EP8 from AliExpress. Had it in my hands in 10 days. The rest of the parts should arrive tomorrow.

 

[ultrajapa]

Looking forward to see your version of the cover once everything is setup.