Here's two pictures. They are a bit outdated now. I have a headlight on front and a battery meter installed in the battery box and a ratchet cable instead of bungee cable holding the box to the frame. Also, the multi-speed freewheel shown has been removed and replaced by a 18tooth single speed. It doesn't have alignment issues anymore or if it does, it's not enough to cause excess noise with the chain. The chain hasn't derailed or broken in the past 2-3 weeks, so it looks like it will hold up now. The single speed freewheel definitely freed things up a bit.
The bike will currently go about 20 miles an hour. (22-23miles in hour if I use a 16tooth freewheel) So given that I only paid about $140 for the entire kit minus the batteries/battery box. I thought it was a pretty good deal.
Couldn't find anything near that price range that I could afford and would have the power I need. It's a 36v system by the way. Gotten from eBay by the way. Sure a few risks associated from that, but the parts I got seem to hold up well for me so I did manage to find a good seller. (except for the freewheel extender thing that came with the kit. That was the only piece that seemed below par quality wise)
I thought about finding a way to put the batteries within the frame for a lower center of gravity, but right now that's where my bike lock is mounted. I have no planes on changing it now since the bike rides fine for me as is and lithium batteries will soon replace the SLA batteries. Box is larger then the batteries by a good 3-4 inches on each side and 4-5 inches from the top. So it's a bit larger then it needs to be, but I didn't have a whole lot to chose from in terms of battery boxes so it was either this one or a smaller one that might have been too small. (note that the speed controller is also inside the battery box) I designed it like that to be a bit more weather proof. I've ridden it in wet weather without issue thus far.
I have a second ratchet cable tying down the batteries inside the box. So rest assured, nothing is moving around in there.
(click to enlarge)
It ain't pretty and some here already said it may be tough to ride but I've had no problems with it. (especially now that I got a double leg kickstand installed). It may ride a bit like a tank, but I don't mind that at all. I've used it like this for the past month and had no issues other then the chain alignment which seems to be solved now.
I never had to use a freewheel tool to "tighten" a freewheel. Simply pedaling it (or in this case having the motor drive it) would act to tighten it. Perhaps your confusing the freewheels with cassettes. They attach to the hub differently and do require tightening with a tool I believe and I've never heard of a single speed bmx bike using a cassette. Only multi-speeds seem to have those.
The couple freewheels I do have, don't even have notches for a freewheel tool. A tool is only needed for removing them. Since the rim and freewheels I do have were cheap, I don't fathom why I would bother trying to remove them.
Last edited by Apache Thunder; 01-15-12 at 01:53 PM.