NEM0 - <$1k Electric Dual Sport

[captainslug]

That bike is screaming for an Astro 3220 setup

Something I'll contemplate when I'm filthy rich.

Captn, I read through all of this at one time or another but I was wondering. Did you test it @ 48 or 60 volts before the freewheel toasted? Looks good btw I love the fabrication.

I tested the pair of motors at 60 volts and reached a top speed of 38mph. They got kind of warm though.

[mwkeefer]

That thing is SICK - very cool looking, a little under powered (my folding bike hits 4200w+) but very cool all the same!

-Mike

[torker]

What is the reason for switching to the treadmill motor? Are you hoping to get more power out of one simplifying the setup? that bike does scream for an astro or mars/etek. I know about the thin wallet thing though

[captainslug]

The sprockets are ordered. Hopefully I can get the chain drive done within the next week.
And better still, a bunch of the guys at work (myself included) are pitching in to buy sand-blasting equipment.
Perfect timing since I that will be the final step in completing this project.

That thing is SICK - very cool looking, a little under powered (my folding bike hits 4200w+) but very cool all the same!

-Mike

Yeah, the peak for this particular motor @60 volts will be around only 3kw because of the cheap controller I'm using.

What is the reason for switching to the treadmill motor?

It's all-around a much more durable and powerful motor, which is also rated far above my intended voltage. If I want more speed later, I can simply up the voltage of the battery pack and controller to reach closer to what the motor is rated for.
Having a pair of motors was also a considerable amount of extra weight to add to this bike. The treadmill motor setup is 20 pounds lighter.

[captainslug]

Replaced the 4awg wires with aluminum bus bars.

[captainslug]

So a bunch of the guys at work pooled together to buy a sand-blasting cabinet. I ran out of work to do by about lunch time so I spent all afternoon and most of the evening using a grinders with brush wheels to strip the frame down to bare metal as much as I could, then used the sand-blaster to do touch ups in the difficult-to-reach spots. I then applied two coats of flat black Rustoleum.

The battery rack is also painted. I'll have more photos to share once the bike is back in one piece.

I apologize for not having any in-progress photos. But the work was really messy and labor intensive. I was afraid that if I stopped to take breathers and take some pictures I wouldn't have reached the point I wanted to be at by this evening.

[captainslug]

Hey Capt'n,

What controller are you using???

If it's a cheap YK-42x series changing a handfull of parts can take it to higher voltages...

Yep
http://cgi.ebay.com/ebaymotors/ws/eBayI ... 0452738030

[captainslug]

Here's the cleaned and painted battery rack I finished working on yesterday.

Reinstalled the electrical system, gauge console, front fender, and controls.

Vinyl dyed the fake exhaust hose black, and lengthened the wires for the turn signals so I could route them through it.

Seen inbetween the bushings is a set-screw collar I made which is flanked by thrust bearings. It makes sure that the axle doesn't slide in either direction.
I also installed the newer and stronger 22T freewheel on the adapter I freed from a previously destroyed freewheel.

I'm now simply waiting on parts to install the belt reduction.

[captainslug]

Bored out both pulleys, tapped one and on the other used a scroll saw to slowly cut a keyway into it.

I've ordered a belt, and parts to make a tensioner for the belt.

[zap]

Very nice build captinslug.
Incredible perseverance on the project... it's amazing how much time something can take when you don't have a set of instructions in front of you eh? And you've done an excellent job of documenting the whole thing.

Good luck with the treadmill motor. I'm using a similar one on a pedal generator and they're nice motors, 1.5hp @ 100v.

[TylerDurden]

Oh Yeah!.... Looking good.

[captainslug]

First stage reduction is complete. The belt tensioner has a flanged sleeve bearing and pivots on the reduction axle.

[captainslug]

This treadmill motor unfortunately is complete garbage and started smoking under initial load testing.

[Malcolm]

This is one of the most stylish bikes on ES, so there's no way you should see it as a failure. Look on it instead as a major step on the path towards attainment of electric motorcycle nirvana.

[gwhy!]

This is one of the most stylish bikes on ES, so there's no way you should see it as a failure. Look on it instead as a major step on the path towards attainment of electric motorcycle nirvana.

Ditto...

Don't give up... just have a re-think.

[vanilla ice]

Oh man that sucks about the treadmill motor. I was hoping that thing would work well.

[TylerDurden]

Yeah, bummer... I was hoping to see a treadmill motor actually work. I guess they always sucked, always will.

The bike is awesome. One of those 12KW outrunners, or a pair of astros might be the ticket.

[TylerDurden]

Thanks for documenting this bike to the point that you've taken it.

+1

For inspiration, or at least a pleasant distraction... check out widodo's thread on alternator conversion:
http://endless-sphere.com/forums/viewtopic.php?f=30&t=16328

[vanilla ice]

Yea I was thinking that also.. the alternator thing goes with the low budget theme of this project. Seems extremely involved though.

[captainslug]

Well, looks like I'll take one last stab at this. I've ordered the motor I ORIGINALLY INTENDED TO USE. A MY1020 rated for 60-volts.

http://tncscooters.com/product.php?sku=106185
The only problem I had with the first motor was that it wasn't able to handle the higher RPMs that resulted from over-volting. It never had any issues with the loads placed on it otherwise.

I also have a plan for mounting it so that I can get rid of the belt tensioner.

[captainslug]

If the single MY1020 rated @ 60 volts proves inadequate, then I have no affordable alternative to consider.
At that point this project will change hands to someone that can afford a more powerful drivetrain.

[captainslug]

Motor is installed. In order to get the pulley on the drive shaft of the motor I had to tap and bore opposite ends of its ID. The thread isn't a perfect match, but its good enough to keep it locked on tight.

The self-retracting extension cord reel fit nicely when wedged into the bottom of the frame. Which I'm very pleased about.

I made a replacement idler sprocket using a cheap freewheel, and an aluminum freewheel adapter from recumpence, which I lathed down a bit and then stuck a sleeve bearing inside of it.

And that's all I could get done today.

[mdd0127]

Don't get discouraged. It's an awesome project, but at 200+ lbs, you're going to need 5-6kw to be reliable and interesting. It's just a fact of physics. If you still can't afford a decent motor by the time I get things really rolling, I'd be happy to donate a motor to your build. I'd start saving for lipos for sure. Again, very impressive build.

[vanilla ice]

I still thinks its a neat little budget moped. The looks is what is throwing everybody off. If you think of it as a dirtbike that happens to have a moped plate, sure the performance isn't up to snuff. If you look at it as a moped that happens to have dirtbike looks, the performance of the original build already had it outperforming ice mopeds.. Any case I understand the desire for higher performance and I hope you find it!

[Jay64]

I hate to see the project end. I truely hope that you get it to work to your expectations. But if you decide to sell it, hit me up and let me know a price. I have a bunch of lithium batts, and a few high power motors. I am always looking for more chassis, and your build is an absolute beauty.