This bike project would not be possible without you ES guys. I have much gratitude for you all. Thank you. The questions you ask are sometimes my questions but often they were not even in my mind and yet so valuable. Many thanks.
Over the last several months I remade my original electric Cortina into a completely new machine.
Motor: Astro 3220 (5 turn)
Primary Drive Assembly: Matt
Tube Clamps: Self made
Tube Clamp to Primary Drive Assembly: 1/8â€ aluminum â€“ Self-made
Torque Limiter: Dalton OSD-225
Motor Drive Freewheel: Try-All 108.9 16t
Controller: HV160 + 2 Caps
Battery: LiPo - 48v 10Ah - 12S-2P 25c
Aluminum Battery-Electronics Enclosure In Triangle: 1/8â€ 3 pieces â€“ self-made
Electronics: Mattâ€™s put the servo tester and BEC into a Radio Shack project box
PreCharge resister: 10 watt â€“ 1 ohm
Rear Hub: Shimano Nexus 3 Speed
Sprockets at rear hub: Combination of Gary Goodrunâ€™s adapter [http://www.tppacks.com/proddetail.asp?prod=EBKE-zz-FWAdapter
], Big Cheese adapter modded to fit the 16t Nexus sprocket, a 50t chainring and Shimano 18t Freewheel
Chains: Human and motor powered drive chains are Wipperman 108 â€“ primary drive chain is #25
Bottom Bracket Cartridge: Sick Bike Parts â€“ 153 mm [http://www.sickbikeparts.com/catalog/product_info.php?cPath=23&products_id=107&osCsid=m0jn9rpbi82vedbkev964e85e4
Bike Frame: Cortina Cycles: Cortina Triton DS â€“ CrMo [http://en.wikipedia.org/wiki/Cortina_Cycles
Forks: Marzocchi Bomber
Rims & Tires: 26â€ â€“ CST Cyclops 26x2.4
Weight: 59 pounds â€“ 33 front & 36 rear
Primary chain reduction: 12:45 â€“ 3.75
Secondary chain reduction: 16:50 â€“ 3.13
Overall reduction: 11.75
Issue: Goes like a bat out of he!! Geared for 45+mph â€“ So far I have had it to about 35mph and it feels very stable.
Issue: Triangle too small â€“ wanted to get 8 packs in but it only has 4 now with the possibility to add another 2 if I work with the wiring in the triangle. The concept is to keep all batts and electronics inside of the triangle. Time to make my own full suspension CrMo frame.
Issue: Throttle is very herky-jerky, especially at lower speedsâ€¦any ideas?
Issue: 3220 gets to about 115 degrees F in just a few minutes easy riding. Is this normal?
Issue: Itâ€™s a PITA to get to the batts for charging. Have to build charging ports into the aluminum coverings.
Issue: Torque-limiter seems to grab and not slip smoothly - feels a bit like a slipping timing belt. Still working out how much pressure to apply â€“ after every ride I adjust it some. This thing gets hotâ€¦I measured over 160 degrees F after a short ride. I think this means itâ€™s slipping a lotâ€¦
Issue: Rear sprocket setup wobbles too much for my comfort. When I stand on the cranks sometimes
the round â€œsplit ringâ€ that holds the 16t sprocket that supports the motor sprocket and freewheel comes off â€“ I think because the center-line of the freewheel sprocket is about 5/8" from the center-line of the 16t hub sprocket. Fortunately, because Garyâ€™s adapter is almost touching the end of the hub and the washers spacing out the adapter from the hub provides a bit of space - I am able, with a small screw driver, to pop the ring back into place. I think if I put some blue Loctite on the split ring it should be OK.
But, the sprocket assembly will still wobble around more than I like.
Issue: Large motor driven rear sprocket is very difficult to make concentric with the axle because of the way the adapter bolts through the 16t sprocket. I am going to take this all apart and see if there is a way I can cut the teeth off the sprocket, I think these things are really hard, and weld on a flange with bolt holes concentric with the axle.
Issue: Need Cycle Analyst but have Turnigy 130A meter for now. Did the "Jeremy Harris mod" to separate the shunt from the display. Works great. Thanks Jeremy.
I am going to rewind an 80x85 and try it out in this machine.
It has occurred to me to rewind a 63-74 and put it in this machine as being more reasonable in terms of power.
Got to move onto a new full suspension CrMo frame. Already have 24â€ wheels and tires and a bike I can scavenge forks and disk brakes and other stuff from.
I will post some video soon.