geared kona dirt jump frame

[flyinmonkie]

Finally got some time to work on the bike. The motor mount is all modified and repainted. I just need to mount the new controller and wire it all up. I also need to get some new sprockets still.

I am trying to work out what size sprockets to get. I am going off the motor being a 150Kv, I think boostjuice said that, and the gearbox being a 9.33:1. If my math is right at 50v that makes the output shaft turn at about 804 rpm. I could be way off. Anyone with a 1200w cyclone running 44.4v lipo know that the output shaft rpm is?

If my math is right, I'll be getting a 20t or 24t to a 55t #25 for the 1st stage. Then a 16t freewheel to 3 sprockets on the rear cluster.

It's coming along.

Clay

[flyinmonkie]

It has been a while now. What can I say? It has been a busy Jan. I still need to mount and wire the new controller. I'll be looking at that in the next few days. I have started an order for some sprockets. They have to get in touch about shipping as it is overseas for them. We will see how that goes. Once I get them, I need to bore one out a bit to fit the output shaft of the cyclone gearbox.

I am keen to get it together, I just haven't had the motivation after long days at work. It will come together soon though. I would like to ride a little this summer.

Clay

[GITech]

Cool!

[sn0wchyld]

keen to see what you've come up with for the cyclone motor! and did you notice that superkids seems to have stock of the big motors again?!

[flyinmonkie]

Thanks sn0w,

I have heard they have stock again, but that are still hard to get a hold of from them.

I have the cyclone now, so I will roll with that. I'll just check the grease regularly. I might adapt it to oil. I'll machine a fill plug so it can be changed easily.

Clay

[TopCat]

Yeah, it looks like thesuperkids dont want to play ball when it comes to ordering one of there motors
I had a mate order me up one of there 2000watters, after a week went bye they refunded his money with no email/explanation as to why?

So with superkids scored off my xmas card list it looks like ill also have to go with the Cyclone motor. It'll probably cost an arm and a leg to get a 650-1200Wmotor-with gear box shipped out to Scotland.
http://www.cyclone-e-bikes.tw/product.php?pid_for_show=3290
Then there's a controller to buy? - sprockets, bits n' bobs for jackshafting. I can hear my paypal account groaning as I type

Im keeping a close eye on flyinmonkie's progress before I go ordering up a motor, especially the wiring up of a controller.

Regards
Tom

[flyinmonkie]

@Topcat
If I remember, they do not ship overseas. I have had everything I have ordered from them sent to a friend in the US. Their customer service seems to be beyond crap now though.

If you are getting a cyclone, email Paco directly and ask him what the shipping actually is. He will give you a reasonable price instead of the insane price the website quotes you.

As for a controller, I went with a lyen and he will send you the wiring info.

As for the progress. I am about to wire up the controller and throttle. I need to get some more andersons though. I also have had to reorder my sprockets as surpluscenter had issues with my last order. I'm not impressed with their customer service, but I'll give them one last chance. I hope to get them soon. I need to get them bored out.

Clay

[bandaro]

Don't bother with superkids, I got the no reply and refund, so I tried again and asked for shipping to australia in the comments box, got a reply that they could do it for 80 bucks. I agreed, emails were exchanged back and forth, the end result is the fuckers promised for weeks that they could do it, but delayed wherever possible. Turns out they couldn't. Wasted like 2 months of perfect riding time.

Anyway, can't wait for some more video's, the bike was so good before.

[TopCat]

@Topcat
If I remember, they do not ship overseas. I have had everything I have ordered from them sent to a friend in the US. Their customer service seems to be beyond crap now though.

If you are getting a cyclone, email Paco directly and ask him what the shipping actually is. He will give you a reasonable price instead of the insane price the website quotes you.

As for a controller, I went with a lyen and he will send you the wiring info.

As for the progress. I am about to wire up the controller and throttle. I need to get some more andersons though. I also have had to reorder my sprockets as surpluscenter had issues with my last order. I'm not impressed with their customer service, but I'll give them one last chance. I hope to get them soon. I need to get them bored out.

Clay

Hi Clay,
There could be good news on the Cyclone motor. After browsing around the Cyclone site I went throught the motions of buying the 650 - 1200 watt motor to see what it would cost. It worked out at...

650-1200W geared motor-cw14T $235 = £149.88
International shipping $123 = £78.46

I then contacted a UK company that does Cyclone Kits and asked if they sell the 650 - 1200 watt motors seperately. I got an email back within hours...

Hi Tom,

The 650 - 1200 watt motors can be sold seperately if required. They come
with gearbox & 14 tooth motor freewheel and cost £129.95 + £9.95 P&P
(subject to exact location).

You would also require controller to be used with the motor which isn't
included in the quote.

It looks like I could save myself some cash ordering up the motor from a UK supplier

After asking about shipping cost to Scotland nearly a month ago I finally got an email from thesuperkkids? A very short email...

$50 US



-------------------------------------------

John - Customer Service

Superkids Online, LLC.

Web: http://www.superkidsonline.com

Email: info@superkidsonline.com

I dont think I'll bother with a reply as thesuperkids are a waste of time.

I think I'll order up the Cyclone motor from the UK. I'll also have to contact Lyen about a controller.

I have sent you a PM.

Regards
Tom

[apyles]

Hi flyingmonkie,

I realize you built this bike a couple of years ago. But I love how your direct chain drive here.
I had a couple of questions on your drive train that I was hoping you could help me with.

1.) What type of hub are you using?

2.) How did you get both freewheels on the hub? Can you provide any more details on this?
( Would this one work? ) http://www.sickbikeparts.com/catalog/pr ... lfntfqs6m7



3.) I would like to re-create your motormount / jack shaft mount. What is the part highlighted here for where the jackshaft goes through is called? Any ideas where I can purchase one?

4.) Any other specifics on how to re-create the motor-mount would be greatly appreciated.

Andy

[flyinmonkie]

Hi flyingmonkie,

I realize you built this bike a couple of years ago. But I love how your direct chain drive here.
I had a couple of questions on your drive train that I was hoping you could help me with.

1.) What type of hub are you using?

If you are asking about the rear wheel hub, it is a standard no name dirt jump bike hub.

2.) How did you get both freewheels on the hub? Can you provide any more details on this?
( Would this one work? ) http://www.sickbikeparts.com/catalog/pr ... lfntfqs6m7

There is only one freewheel on the rear wheal hub. I had it splined by liveforphysics. I think thud will spline freewheels for you. They need to be a white eno though. The motor drives through the standard bike sprockets. I only use 3 from a cassette.



3.) I would like to re-create your motormount / jack shaft mount. What is the part highlighted here for where the jackshaft goes through is called? Any ideas where I can purchase one?

I would call it a bearing tube. I had it all custom made, so you can not buy on like it. You may be able to find something somewhere, but most people are having them made. If I had to do it again, I would make it for more standard 1/2" id bearings. The ones I use a really small and not very standard. If you look through the whole thread, you will see I changed the mount that holds that part on the bike. I could have used a standard bike stem it the seat tube on my frame where smaller. I had one made custom to fit my seat tube and my motor mount. It works a lot better. There was a lot of flex in the old bracket.

4.) Any other specifics on how to re-create the motor-mount would be greatly appreciated.

Make it to fit your motor and bike. Or order a V2 (I think) drive from recumpence and adapt the motor plate to fit your motor. I based my design on his. Mine is steel and heavy though. His is cnc'd out of aluminium and a lot lighter. He also has feet and frame clamps that are amazing. If it weren't for shipping and the exchange rate to NZ, I would have gone with one of his drives and adapted it to my bike.

Andy

Good luck and I look forward to seeing what you come up with.

Clay

[flyinmonkie]

Sprockets arrived and are getting bored out some time next week. Now just waiting on some more andersons. Should be wiring up what I can, but I'm off to bottle beer instead.

Clay

[GITech]

Hehe!

Can't wait to see the results +beer!

[flyinmonkie]

Beer made it in the bottles fine. Now just have to wait 2 to 3 weeks for some carbonation.

As for the bike... The sprockets needed for the cyclone are so much smaller. Having the gearbox really helps. The driven sprocket on the first stage will no longer be just under my seat. I'm looking forward to having it all a little smaller.

I might do some wiring this avo. Then again... Might brew the next batch of beer.

Clay

[flyinmonkie]

Sprockets are back and they fit great. I have started wiring up the lyen controller. I have the power side all sorted. Batteries a fuse and the main switch. I am starting on the halls and throttle as well. I am waiting for some connectors to finish the phase wires.

I have to line up the sprockets and probably make a chain tensioner as well. After I sort the chain line, I think I will be able to trim both the motor output shaft and the jackshaft a little bit. That will make it a little narrower over all. It all fits between the cranks as it is, but narrower is always a good thing when it comes to an ebike drive.

Not long before I am running again.

I'll get some pics up in the next couple of days.

Clay

[flyinmonkie]

All wired and everything seems to be fine with the electronics. The motor spins and it seems no louder than my brushed motors. I'm not sure what the complaint about the sound of the cyclones is.. yet. Of course I haven't run it under load.

I need to set up a chain tensioner and the chain line for the motor. Then I can go for a test hoon. I'll be working on that shortly and I get the promised pics. There really hasn't been much to show as of yet.

I will still have a lot of tidy up on the shaft lengths and finishing the top of the box. I also still need to set up my one plug charger. All those details take so much time when I would just rather ride. Oh well... off to the work shop.

Clay

[flyinmonkie]

After a long day yesterday, I got the bike to a ridable state. The short test ride went well. I need to dimple the shafts to make it totally ridable, but it feels really solid. Even more so than the brushed motors did. It is also about the same volume as the brushed motors, just a little deeper. It isn't really that loud at all.

That leaves finishing the top of the box, the one plug charger setup, and painting the box.

I'll be riding to work again next week.

The gearing needs to be adjusted as I topped out at 37kph and I want 60 again. I thought that might happen from the gearing math I did. I just need to change the sprockets on the rear hub. I should be able to get what I want.

I promised pics, so here they are finally. They aren't the greatest as it was dark and the flash glared a bit.

[sn0wchyld]

looking great mate.

looks like you have heaps of space for batts too! Hows the noise of that cyclone now that its lost it's gearbox?

[TopCat]

Looking good Clay, looks like your back in business mate

Can I ask about your sprockets n' chain. What size are they and where did you get them?
Especially the on on the motor.

looking great mate.

looks like you have heaps of space for batts too! Hows the noise of that cyclone now that its lost it's gearbox?

Looks to me like the gearbox is still on the motor. The square box to the left of the white line on the motor is the gearbox?

Regards
Tom

[flyinmonkie]

@ sn0wychyld

Thanks, yup there is room for 4 more batteries. That would give me 23.2 amp hours at 50v off the charger. I only have 4 batteries at the moment for half the amp hours at the same voltage.

the gearbox is still on the motor and it is quieter than my old brushed motor. My wife could hear me in the house when I was coming up the road with my old motor. She can;t hear this one until I turn in the drive. It is a lower pitch as well.

@ topcat

I got them from surplus center in the US.

https://www.surpluscenter.com/sort.asp? ... 0&PageNo=1

I had to have them bored out to fit the motor output shaft and my jackshaft. They and the chain are #25.

I went for a good test ride after topping off the bats and changing the gearing. It runs well. I now have a 28t, 21t, and 14t on the rear. I top out at about 45kph now. It is slower than I would like, but smooth and solid. It will climb most anything in the lowest gear. I may change the driven gear on the jackshaft to get a higher top end.

It has good acceleration off the line, but then tends to take a while to wind out to the end of the gear. My old motor just accelerated to the end of the gear. It is kind of like a diesel vs a petrol car. It just keeps going even when under load though and it is hard to bog down.

Stats
42 amps max
1999.9 watts max

That was from a dead stop on a hill and it started and accelerated up the hill.

I can't stress how solid it feels. I also don't get why people think they are loud. It might get louder as the grease wears out, but that will be a sign to re grease it.

After the ride, the motor was warm and the controller was air temp. I am pretty happy overall.

Clay

[bandaro]

Looks very nice, good to see it's back up and running.

I have a components question as well though, first is how long does the #25 chain last for you, and second is regarding the axle, how big is it and what steel? I shredded a 12mm mild steel one of mine within minutes, so was thinking of going a 15mm hardened shaft.

[flyinmonkie]

Looks very nice, good to see it's back up and running.

I have a components question as well though, first is how long does the #25 chain last for you, and second is regarding the axle, how big is it and what steel? I shredded a 12mm mild steel one of mine within minutes, so was thinking of going a 15mm hardened shaft.

Thanks, I haven't replaced the #25 chain yet and it has been on the bike from day one. It has over 1000kms on it.

The shaft is 13mm I think. I can't remember. It might be 15mm I had it specially made to fit a US Cycles freewheel adapter. It isn't hardened as I could easily drill dimples in it and cut it down. I haven't had a issue with it yet.

Clay

[flyinmonkie]

I changed the programming on the 12 fet Lyen controller and it is much better. It pulls hard right to the end of the gears now. I also see 50kph on the flat as well. I am pretty happy with the set up now.

I need to put a proper plug in the hall wires. Then I need to finish the top and it will be done. (...for now)

When I get it sorted I'll work on some rid videos.

Clay

[AussieJester]

Great too see her up and running again AmericanKiwiDude im sure she will be
a hell lot more reliable than the brushed motor Dont get the whole noise thing
either mate, once your over 25km/hr you can't hear anything for wind noise anywayz so what the frock does it matter LoL

KiM

[flyinmonkie]

Great too see her up and running again AmericanKiwiDude im sure she will be
a hell lot more reliable than the brushed motor Dont get the whole noise thing
either mate, once your over 25km/hr you can't hear anything for wind noise anywayz so what the frock does it matter LoL

KiM

Hey, Kim has come up for air. Make sure you get some food to keep the energy up while you are taking out. he he

Thanks Kim, good to see you. Have you done anything on the HOBO lately, or too busy with the woman?

Clay