Electric "tough bike"

vax · Mar 11, 2012

Hello again. This is my 6th build so far, and it started in Solidworks.
The idea is pretty much same as for Stealth Bikes - rugged aluminium monocock, maximum shock travel.
However, I'm using 20'' BMX wheels to lower centre of gravity and enhanche agility.
So far I have 3 components waiting - Velectris Phantom hub motor, Kelly KBS48051 controller (48V, 20A) and Marzocchi 888RV fork.
Rear shock will be from CZ motocross bike, pressure air type, it's really light and has great adjustability.
Batteries will be ThunderSky 48V 20Ah LiFePO4, which should arrive soon.

rojitor · Mar 12, 2012

Right now at solidworks looks just great, i like that bomber style. Will 48v be enough? Haha i got addicted to 72v

vax · May 16, 2012

Some updates:
The battery is still on the way, latest promise is 20. of June.
The BMS has arrived, it's made here in Estonia by company called "DriveCord". It's modular, consisting of slave boards and master board and can be used in various battery systems. Actually it's also used in some electric cars and so far works great.
http://www.zev.ee/files/uploads/LiYFePO2.jpg
http://www.zev.ee/files/uploads/L2e_pic6.jpg
I'm still waitng of custom made stainless spokes from Czechs republic, it's been over a month now...
However, the front end is at my table, and I really like the look

[already did some eyeballing sessions]

Hillhater · May 17, 2012

Seems too nice to be limited by a 48v, 20A controller ?

miuan · May 17, 2012

vax said:
I'm still waitng of custom made stainless spokes from Czechs republic, it's been over a month now...

Did you order at Šroubárna Marek? They are not the fastest. What rims and spoke guage are you using?

vax · May 17, 2012

miuan said:
vax said:

I'm still waitng of custom made stainless spokes from Czechs republic, it's been over a month now...

Click to expand...

Did you order at Šroubárna Marek? They are not the fastest. What rims and spoke guage are you using?

Don't know exact manufacturer, I ordered them from local motorcycle shop. 2mm diameter, 128mm length and I'be using same rim as in front, that is 20'' BMX...
The guy at bicycle shop said X1 pattern is possible. I hope he's right.

vax · May 17, 2012

Hillhater said:
Seems too nice to be limited by a 48v, 20A controller ?

It's a start. I don't have too much financial resources right now, so it have to be enough. The batteries and BMS alone are quite expensive.
Also, the motor I have (Velectris Phantom) is labeled as 250W.

vax · Jun 8, 2012

Finally, spokes arrived, but someone had made a mistake, there's 30 (+3 spare) spokes instead of 36.
I lied previously, didn't remember correctly - those are 3mm stainless spokes, very nice and strong.
I had to enlarge the holes to 6mm on the rim, and to drill at angle for correct spoke placement.
The spoke pattern is 2+1, because I messed up with calculations and spokes were too long for X1
But here it is:

Sorry my english...

vax · Aug 23, 2012

My Extra 3 spokes arrived from Taiwan... At last. However, I had a deal with local EV company for battery delivery, and it's also dragging behind. So, still no sign of batteries (they gave me BMS boards though).
Today I made new, simpler version of my frame - now it's pretty much just two 5mm aluminium sheets, that are held together by battery box, steering column and suspension axle. I really like it this time, it's so minimalistic and easy to fabricate. All the good things must be simple

It's missing a saddle post and rear spring/shock right now, because I ran out of clear ideas. Maybe tomorrow, with large cup of strong coffee

buzzfirst · Aug 23, 2012

I like this frame a lot. It looks like it could be built by far more people than a tube frame. Cad layout of the frame sides and a few

more details looks doable. Keep at it for all us non tube welding guys.

vax · Sep 3, 2012

Today's progress. Still minor bug fixes to do, but overall it's nearly complete.
Rear shock will be CZ motocross air shock (from 70-s). Easy to adjust height with air pressure.

vax · Sep 13, 2012

Some bug fixes: smaller cutaway sections in the frame; battery covers added (GRP or carbon)

vax · Feb 19, 2013

Time has seriously passed, but project hasn't stopped. Just delayed by battery deal.
Today, however, my batteries arrived at last.
I didn't want to make any frame construction before batteries lie on my desk. So I made cardboard mockup:

spinningmagnets · Feb 19, 2013

Ahhhhh!...Cardboard-Aided-Design (CAD), one of my favorite techniques! Looks great, and even if I wanted a different frame style for myself, builds like this will document clever DIY methods that are very useful to the group.

jpgey · Feb 19, 2013

vax said:
Time has seriously passed, but project hasn't stopped. Just delayed by battery deal.
Today, however, my batteries arrived at last.

Nice to see an ebike with this kind of battery

vax · Mar 21, 2013

News again. Aluminium pieces arrived from laser cutting and I spent two hours trying to produce exact bends. First ones were a bit overshoot, but those were fixed by rubber mallet beating.
Most of the bends are 10 degrees, except for saddle carrier, which has 8 degrees incline.
I thin I make all the files freely availavble to anyone once it's complete.

pendragon8000 · Apr 4, 2013

Cool design. Like a stealth bmx ...? Looks like it won't weigh too much.
Have you done any welding yet?

vax · Apr 10, 2013

Received my 48V 5A charger from Ping. Seems decent construction.

vax · Jun 6, 2013

The frame is going to welder next week (at least I hope), so I'm prepping all the pieces and drawings.
Bought rear suspension bearings, cheap ones, for welding - outer bushings are welded to sheet aluminium around and those pieces are centered by shaft and bearings.

pendragon8000 · Jun 7, 2013

I think you should triangulate in 3 dimensions. I just put a few lines there to show what im thinking.
I mainly was motivated to post this because i have had my last build frame warp and almost snap after many moderate jumps, 200 or so Kms..
its now solid as with some 3d triangles.
edit
sorry if that was a semi constructed photo...

vax · Jun 7, 2013

Yes there's some details missing at the photos. See 3D renderings for reference.

vax · Jun 9, 2013

Some new pictures:
- steering column

- last minute reinforcements

- saddle post diagonals

- rear shock

- rear suspension assembly

jansevr · Jun 10, 2013

very cool project!

xadmx · Jun 10, 2013

pendragon8000 said:
I think you should triangulate in 3 dimensions. I just put a few lines there to show what im thinking.
I mainly was motivated to post this because i have had my last build frame warp and almost snap after many moderate jumps, 200 or so Kms..
its now solid as with some 3d triangles.
edit
sorry if that was a semi constructed photo...

Is the rear swing arm made from 5mm it looks like its going to twist side to side to me. Clamp a wheel or block in the rear drop outs and see if you can bend the wheel side to side.
Adam

Willow · Jun 23, 2013

...I have similar concerns at the 'V' in the side plates near the neck. There is potential for a lot of sideways deflection, and also potential for cracking at the corner of the 'v' - aluminium fatigue can be very serious - especially at high stress points. The neck will exhibit extremely high stress loading under normal conditions.... good luck with the build - it's looking good.

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