Electra-punk

[sn0wchyld]

Cheers

WOW
that looks tidy! makes my wiring look like a loom of S#!T. Cant wait to get the time to put together a new bat case, so I can make mine look like that.
Do you need to reconfig for charging?

[rodgah]

Do you need to reconfig for charging?

nope....the db25 connector at the bottom has all 12s cells or 14 pins for balancing and the remaining pins share (-) and (+)....5 each. This is not a new technique, I am copying what alot of people have already done, and it is a neat solution to balance charging lipo.

dont worry, i think everyones first attempt looks terrible, mine looked like abortions thats for sure, but the more times you do it, the more you get a feel for how to make it neater and simpler.

cheers

[sn0wchyld]

Do you need to reconfig for charging?

nope....the db25 connector at the bottom has all 12s cells or 14 pins for balancing and the remaining pins share (-) and (+)....5 each. This is not a new technique, I am copying what alot of people have already done, and it is a neat solution to balance charging lipo.

dont worry, i think everyones first attempt looks terrible, mine looked like abortions thats for sure, but the more times you do it, the more you get a feel for how to make it neater and simpler.

cheers

I think I might be doing something similar already, only I still use the discharge leads for charging too, rather than through the db25. I still have to reconfig as my charger only manages 8s charging, and im running 20s. Using the spare pins for the main leads is a good idea, but how many amps can the pins take? Im charging at 30-40A, so not sure they'll take that...

[flyinmonkie]

rodgah

The bike looks amazing. I like the battery box. Looks very similar to what I am doing. I'm looking forward to seeing how it all fits together.

Clay

[rodgah]

Ok time for an update.....

-I have mounted the box and cut the window
-had the BB welded to the brackets
-received the order from Matt.S
-made the battery mount.


Things i have left to do....

-go and pick up the box lid/cover and mount it using m6 nutserts
-buy chains
-modify rear brake caliper mount to allow the caliper to move over and slot over the disc
-pick up the new front fork stanchions
-assemble and mount drive
-wire everything up


The sprocket adaptor that Matt machined fits perfectly....has enough space for the caliper to sit in beside the sprocket. Unfortunately choppersUS hubs are a little oversize, so I threw the adapter on the lathe and opened it up a fraction to accept the hub.



spacing....


The rest of the pictures are at the start of the thread as usual.

Cheers

[recumpence]

I am amazed at the continual improvement I see in project bikes coming out of this forum as time goes on.

Amazing......

Matt

[kfong]

Another cool build!

[rodgah]

thanks guys,

anyone interested in weight,

I just weighed all the parts on the bike, only missing the chain for the drive to backwheel and it came in at 36.5KG's, alot lighter than I first thought it would be.

more updates next week.....

Cheers

[SamTexas]

Subscribed. I'm amazed at the skill and effort you put into this build. Is this a common trait among downunder's members? More pictures please.

One question: Since you were building from scratch, why didn't you make the battery box part of the frame?

[rodgah]

Subscribed. I'm amazed at the skill and effort you put into this build. Is this a common trait among downunder's members? More pictures please.

One question: Since you were building from scratch, why didn't you make the battery box part of the frame?

++

thanks, I think its just because we are all anal f**ks and like to be perfect

weight/design.....

assuming it were made out of 0.9mm ally like originally planned it would of been lighter(though in retrospect it would of been easier to have it laser cut in SS and welded to the frame). And besides I love the contrast between stainless steel and machined/polished aluminum(it is going to be polished, just waiting to be finished handling it before I go finishing it). And trying to replicate / redesign a vintage ICE bike to some degree requires something that looks similar to a fuel tank.

I have not had alot of progress this week, still waiting on chains, new drive mounts (the originals were too short). I am having a crack at the wiring....probably 50% done, and hobbyking have held an order of mine containing cable sheath that I want to use to complete this bike because it went into backorder as I ordered it . Might be going before Christmas lol .

I did shave the brake caliper mount though so I have functional rear brakes

Cheers

[rodgah]

added more pics in the first pages
few of the bike and one showing the rebate on the disc brake caliper mount in order to get it to line up with the disc.

[rodgah]

Wired everything today not a lot left to do now.....

Final pictures of the bus bars and balance setup added.

Cheers

[Whiplash]

Absolute work of art, one of the very best builds on the Sphere in my opinion! I love the detail work and the simplicity of the look! You are one hell of a craftsman!

[rodgah]

Absolute work of art, one of the very best builds on the Sphere in my opinion! I love the detail work and the simplicity of the look! You are one hell of a craftsman!

Thanks whip.....sometimes I stand back looking at it an go 'wow' myself lol

[doc007]

that is a sweet build! it looks like you are running a floating disc brake. when you get a chance can you show some more pics of it?

[rodgah]

that is a sweet build! it looks like you are running a floating disc brake. when you get a chance can you show some more pics of it?

its a hope mono floating disc. Plenty of members on this forum use them....
http://www.chainreactioncycles.com/Models.aspx?ModelID=16457


Bike is now running, I got the forks, new motor plates, chains, mounted everything up. Goes like a dream, so smooth and stable. If I really nail it, the hv160 hits its current limiting, I may adjust the clutch so this doesnt happen or up the current limit. No wheelies but it takes off like a rocket, pulls some weird looks while I'm riding along with traffic thats for sure .

Few pics added, one of the finished forkleg and one of the new mounts for the drive. Im still waiting on the lid for the box and also some quick release screws from pro-bolt ......



And I still have to disassemble it and finish off all the parts removing all the sweaty hand prints and weld splatter......adding some loops to the frame and fork too to tie the cables to.

Ill post some final pictures and videos once this is all sorted.

Cheers

[rodgah]

pics added of the box lid and the cable tie points on the frame. I have cleaned/refinished all of the frame and box for final assembly, even painted the BB tube since rust doesnt really suit it .

Waiting on some goodies from Matt/Recumpence and she will be finished

On a side note, my welder friend is making a duplicate of this frame only a fraction heavier. He wants BIG power.....biggest you would seriously throw in it. I said OK AGNI 95R it is . He wants to use speedway solo bike wheels (nice and light) and no pedals just pegs. Throw in a butt load of lipo and I'm sure it will have some poke.

Rodger

[recumpence]

Cool!

Your box shipped out yesterday "Express Mail". It is guaranteed to be there next Tuesday.

Make sure you get a build thread started on that Agni bike. I am interested in seeing that too!

Matt

[etard]

Amazing work Rodgah! Is the slipper clutch engaging at all as far as you can tell? Have you tried "locking it out" to see the difference? I would like to see a pic with you on it just to get a size comparison.

+1 on Agni bike pics!

[grindz145]

Omg, that thing is gorgeous. I'm really interested in people who are bringing art together with ebike technology. We're lacking design. Fantastic work.

[rodgah]

Cool!

Your box shipped out yesterday "Express Mail". It is guaranteed to be there next Tuesday.

Make sure you get a build thread started on that Agni bike. I am interested in seeing that too!

Matt

Thanks Matt though I have no faith in the postal system delivering any of its promises. I can get stuff to my doorstep faster from Chain reaction or hobby king china than I can from the neighboring states in my own country, but by far the slowest is usually from US/Canada. And even when they guarantee it and its late they blame it on customs . Either way thanks a million .

Etard the slipper clutch does slip from time to time(when I really give it curry). It is an odd feeling, and coming from a racing background I find it hard to ignore and keep powering on as usually feeling that meant back off before you cook the clutch pack contaminate the oil and wreck the engine. I have tried locking it out and the amps do peak higher, the bike doesnt feel like its lost alot of power by having it slip, but it makes a dramatic difference to the Amp peaks it was pulling.....so it does its job well. There is a video some pages back of when I first got it rolling to show the size of it......I will get some pictures in the future.

thanks grindz145

There will be a thread for the agni bike but it wont start till after christmas

Rodger

[rodgah]

updates on the first page


Added a photo of the charger lead

Added photos of the new davinci drive bracket and fan cooled 3220 ......Thanks very much Matt.

The new bracket sinks ALOT of heat away from the motor, it is just about uniform temp with the motor can. Due to my motor not having any room between the end windings and the front of the can I was only able to drill inside of the rotor gap.....well I was too scared to drill in and see if Id hit the windings LOL. The fan doesn't flow massive amounts of air (very much due to my limited amount of opening) but it blows enough that I can feel it exhausting hot air once the motor gets warm. I think a good comparison would be a dremel at full RPM....about that much air. What I can say is it makes a definite difference to the motor heat, I got bored of being abusive testing it to see if it would over heat, it just stabilized at 60degC and didnt move any higher, though anywhere where I could of coasted, I was instead keeping the motor spinning to keep air moving through it.

I think if you were in the market for a 3220, you would be silly to pass up the big shaft, big bearing, fan cooled model Matt is producing.

Ill hopefully get a few videos in the next few weeks.

Cheers

[recumpence]

That is very good news, indeed.

I have a few new things up my sleeve as far as additional cooling is concerned.

Anyway, I love this bike. I am sooooo glad the heat issue is resolved.

Matt

[GITech]

Wow, this is really nice!

Almost all stainless too!

Can't wait to see it go!

Wow,
Jay

[sn0wchyld]

sounds good mate! makes me wish I had the $$ to front for what sounds like a near bullet proof motor!
Any thoughts on the possibility of running the fan of a small low watt high rpm motor, like a blower fan off a laptop or something? that way you'd have continuous cooling even when stopped, at the cost of just a few watts or so? removes the drag of the fan off your driving motor too (though I doubt its enough to warrant the 2nd motor for this reason alone)