Electric "tough bike"

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vax
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Re: Electric "tough bike"

Post by vax » Jun 26, 2013 5:16 am

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Prototype fabrication https://www.facebook.com/3dflux

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mushymelon
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Re: Electric "tough bike"

Post by mushymelon » Jul 07, 2013 12:14 pm

Looks great.

You may want to consider more reinforcement up front.
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Cheers

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vax
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Re: Electric "tough bike"

Post by vax » Jul 27, 2013 10:04 am

Some porn.
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There was quite a hassle with frame welding. At first try the rear arm ends bent inwards, so we made vertical cuts to already welded arms, bent them straight, welded support plates to keep them parallel and then at last welded the cuts together. And the whole frame spent some hours at oven @ 220C for stress relief. Today I cut support plates away and it stayed parallel.
Ther's rear suspension missing entirely yet, this, and rear dropouts are next big jobs.
Prototype fabrication https://www.facebook.com/3dflux

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jansevr
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Re: Electric "tough bike"

Post by jansevr » Jul 27, 2013 10:17 am

wow - its looking awesome! very nice welds as well =) whats the weight at as pictured above?

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pendragon8000
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Re: Electric "tough bike"

Post by pendragon8000 » Jul 28, 2013 5:28 am

vax wrote:Some porn.
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There was quite a hassle with frame welding. At first try the rear arm ends bent inwards, so we made vertical cuts to already welded arms, bent them straight, welded support plates to keep them parallel and then at last welded the cuts together. And the whole frame spent some hours at oven @ 220C for stress relief. Today I cut support plates away and it stayed parallel.
Ther's rear suspension missing entirely yet, this, and rear dropouts are next big jobs.
Awesome.
What do you think of geometry?
Small 20" wheels? Hard to tell what it would be like to ride, I suspect nimble and plush.
Btw awesome 3d triangulation of the swing arm. Very cool
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sk8norcal
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Re: Electric "tough bike"

Post by sk8norcal » Jul 30, 2013 11:35 pm

looks good,

never ridden motocross bikes,
but seems like ur peg position is off...
ideally peg position be adjustable, no?

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vax
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Re: Electric "tough bike"

Post by vax » Aug 01, 2013 9:30 am

All I can say right now, that seating position will be more mtb than mx.
The saddle will also be mtb one, the saddle post attachment point will be at the top of "pylon".
Right where are two bolt holes, seatpost bracket will be between them.
Prototype fabrication https://www.facebook.com/3dflux

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Re: Electric "tough bike"

Post by torqueboards » Aug 28, 2013 12:23 am

That's an awesome frame. Amazing work. Sure beats the price of those expensive ebikes. Reallly Really Great bike. I've been lurking the E scooter/ebike posts and man the E Bikes are ridiculous.

Sweet build. Wonder how a 72v would be.
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vax
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Re: Electric "tough bike"

Post by vax » Sep 11, 2013 11:50 am

I'm currently messing around with rear suspension linkage, basically it will amplify movement of rear swingarm, progressively.
Partly, because I found that my rear spring was too weak for my weight :D
Prototype fabrication https://www.facebook.com/3dflux

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oatnet
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Re: Electric "tough bike"

Post by oatnet » Sep 11, 2013 11:55 am

Just came across this - I've been working on a similar design, I look forward to seeing where you take this!

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meelis11
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Re: Electric "tough bike"

Post by meelis11 » Sep 12, 2013 2:46 am

Nice looking, has lots of potential. But that 250W hub seems little underpowered for ebike with looks like this.
First thing is to get it running, can upgrade later if you need more power :)
I want to see it when it is running, I am from Tallinn :)

Meelis

vax
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Re: Electric "tough bike"

Post by vax » Sep 15, 2013 9:34 am

About 250W hub:
It's all about being street legal. In real life I'm sure it can handle much more power. Also, I'm using 48V instead of 36V marked on the hub.
There's some issues, however. For example, I have to upgrade wires, current ones are really thin and will cause problems.
If I blow the motor, I can rewind it with thicker wire and less turns.
Prototype fabrication https://www.facebook.com/3dflux

vax
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Re: Electric "tough bike"

Post by vax » Oct 16, 2013 1:47 am

Updates:
Installed rear shock
Installed front brake, 203mm disc with Avid Code 4 piston caliper
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Prototype fabrication https://www.facebook.com/3dflux

vax
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Re: Electric "tough bike"

Post by vax » Oct 22, 2013 1:56 pm

Front brake assembled.
Avid Code caliper with 203mm disk.
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Prototype fabrication https://www.facebook.com/3dflux

vax
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Re: Electric "tough bike"

Post by vax » Nov 16, 2013 12:22 pm

Rolling chassis.
Faults:
1. Rear spring too soft
Where to obtain? I reckon pitbike spring will be ok
2. Both tires flat, forgot to use spoke rubber ring...
3. Rear swingarm needs new bearings and proper assembly.

Next, I guess, will be electrical assembly.
There also will be small 40cc range extender.

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Prototype fabrication https://www.facebook.com/3dflux

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dr_frost_dk
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Re: Electric "tough bike"

Post by dr_frost_dk » Nov 19, 2013 10:26 am

Bookmarked!.
My DM50 is fun as a conversion but it is truly awesome to see a PURPOSE built EV, Awesome job so far :), Looking forward to see it go when you get it finished.

vax
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Re: Electric "tough bike"

Post by vax » Dec 22, 2013 9:00 am

Did first ride today.
I manged to fry one of the BMS boards, I'll get a new one tomorrow, costs 14EUR...
So, today, I hooked up temporary wiring and headed to street. It was wet and cold, so I only did couple of Kilometers.
As I suspected 20A @ 48V is not very thrilling ride. So, 50A controller with better motor will be next goal.
Said that, I must admit, that the chassis is success. It handles very nimble, suspension stiffness just the way I like it.
It's quite long frame and seating position is pretty foward leaning. Add very hard saddle, meaning it's not very comfy ride.
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Prototype fabrication https://www.facebook.com/3dflux

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jansevr
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Re: Electric "tough bike"

Post by jansevr » Dec 22, 2013 1:03 pm

looks good! glad to see you finally have a running bike! you definitely need to get a more powerful motor - how about a cro motor :D and a different seat would probably be a good idea too. also i might have missed this at some point - but whats the capacity of the batter pack?

vax
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Re: Electric "tough bike"

Post by vax » Jan 01, 2014 6:42 am

jansevr, the battery is 20Ah.
Yes the motor is not very powerful, and it is slow too - must be low RPM motor. It doesn't go faster without load...
However, 1kw Kelly and motor doesn't get warm at all. Motor has 250W printed on side cover :) Maybe 50A kelly next?
I'll have a look on Cromotor.
Prototype fabrication https://www.facebook.com/3dflux

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Re: Electric "tough bike"

Post by ricklearned » Jan 01, 2014 8:13 am

Looks like those BMS boards could short on opposite battery terminal. Have you considered a centralized BMS?

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Re: Electric "tough bike"

Post by 100volts+ » Jan 01, 2014 11:48 am

subscibed
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Re: Electric "tough bike"

Post by angelo212 » Jan 20, 2014 9:41 pm

That is a beautiful work you did. Subscribed.
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Re: Electric "tough bike"

Post by vax » Jan 27, 2014 1:26 am

ricklearned wrote:Looks like those BMS boards could short on opposite battery terminal. Have you considered a centralized BMS?
Yes, I thought that could happen, and put extra insulation under bms boards.
Updates,
I'm currently building proper electric systems - solid state relays for switchoff, Dc-Dc for 12V systems.
The bms main board uses 12v since it' designed for cars.It has two 2A relays, that switch over, when one of the slave boards breaks loop circuit. I'm gonna use one of relays to feed the bms itsself (with parallel ignition switch) and other to drive main solid state relay. This way, when bms disengages relays, it's gonna auto-shutdown.
Prototype fabrication https://www.facebook.com/3dflux

vax
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Re: Electric "tough bike"

Post by vax » Feb 13, 2014 3:29 pm

I published the project files to GrabCAD.
https://grabcad.com/library/electric-mo ... onocoque-1
Prototype fabrication https://www.facebook.com/3dflux

vax
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Re: Electric "tough bike"

Post by vax » Feb 15, 2014 6:23 am

Designed stainless steel (0.8mm) side covers couple of days ago, they are being fabricated right now.
There will be foam insulation inside, both for temperature and electrical.
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Prototype fabrication https://www.facebook.com/3dflux

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