Electra-punk

rodgah

10 kW
Joined
Dec 23, 2009
Messages
553
Location
Sunshine Coast, Australia
My new project.....

I have always loved vintage bikes, never really wanted to own one just admired them for the simple ideas and the infant motorcycle design. In some ways I think bikes on endless sphere share the same characteristics, so Ive decided to build a bike following the same basic lines but electrically powered ..... kind of like a tribute I suppose.

Details are....
Frame
- 25mm Stainless Steel box 1.2mm wall and 50mm tube
- Brackets and braces laser cut
- Aluminium battery box
- 66deg head angle
- 80mm wide 26" rims, rear superwide 170mm hub(chopperUS)
- Schwalbe Fat franks stretched out
- ChoppersUS tripple tree forks.....modded with my own fork legs
- Chain lengths individually adjustable

Drive system
- 3220 5t wye in a MS single stage belt drive, 60T rear sprocket mounted on a MS adapter (geared for only 60km/h)
- CC HV160
- MS Magura and servo tester throttle adaptor
- 20AH of 12s lipo

Misc
- Hyperion 1420i Charger
- Hope tech m4s


Frame
Frame layout....
bike.jpg
bike2.jpg

Laser cut parts done...
parts.jpg

Basic frame complete
cdf4fbbf.jpg

11baeffb.jpg

cde4cb04.jpg


Frame box done.
27fb06cf.jpg

bc30567c.jpg

2cadabb1.jpg


Frame box mounted
6c06c389.jpg


BB tube welded and mounted
510069fd.jpg


Bit more progress....
2fd1792e.jpg

555dfb34.jpg

9c3bbad6.jpg

Might be a little hard to see in the pics but the large belt pully is touching the lower drive mount so I had to get the drive mounts recut a bit taller and out of 5mm......

Frame box cover done....with quick release 1/4 turn screws in anodized blue....hard to get a good picture in low lighting
026a0f98.jpg


Loops welded to the frame and fork leg to tie the brake lines to...
6402f087.jpg


Frame Finished

Forks
So the Forks from choppersus were not discbrake compatible(they were out of stock). So I am making new fork legs in stainless tube and brackets to match the rest of the frame.

Dropout and disc tab with jig and spacer to offset the tab 4mm as the standard(plus the washers for a bit extra adjustment)
a5aad62a.jpg

9dae870e.jpg

11219546.jpg


Forks Finished

I will keep adding updates to the start of this thread.....hopefully

Cheers
Rodger
 
Electrical

CA-RC, HV160, Astro 3220
10ecb789.jpg

Edit: Not using CA-RC on this build, using a servo tester throttle interface from Matt

Drive parts
7f718904.jpg

Drive mounts
20a84c79.jpg


Parallel / Series Bus bar setup ....
0ee49370.jpg


Balance harness/board and charger plug on battery mount
dffaa2c5.jpg


Complete
39581f13.jpg



Drive system Complete
 
Misc

For the charging side of things I have a Hyperion 1420i, and 2 meanwell 24v 350watt supplies. I decided to make a shelter out of zinc anneal to house the parts and protect any wandering fingers from 240v mains.

Laser cut sheet
5670b49d.jpg


Hand folded and assembled. SS m4 screws and the tabs are just to allow the wiring to be wrapped around it.....needs some paint.
b68c085a.jpg

fdcdb9fa.jpg

Painted.....28s balance charging anyone lol.
bfa9d2e9.jpg

Charge lead
0bae2920.jpg


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.

de44edd5.jpg


and the result spacing
0179a994.jpg


and after rebating the caliper mount to move the caliper over...
cd623281.jpg


Finished
 
I wish I had a local lazer cutter!! Looks great!
 
update guys, frame is finished(up the top pics), needs the box and BB mount which I will add in a few days. Still waiting on choppersUS headset bearings + reducers (they sent me the wrong size forks) which has been sitting in USPS sort facility since the 22nd of august, so hopefully the tracking is wrong or I think its been lost.

Things still to go till I have complete bike of parts
-headstem bearings + reducers
-v4 belt drive (hopefully Matt will be sending soon)
-frame box and BB
-Fork legs welded
-Chain ring + freewheel + a couple of chains

Cheers
 
As I said in msn yesterday Wodger! :p Love the front half, the rear, just IMHO, looks erm.."wrong" I understand its for chain alignment purposes and all but fpr the price you paid to have it fabricated for you, I would have liked to seen something lil more "elegant" lets say LoL.. Its quite simple to achieve chain clearance using more traditional looking seat/chain stays.

Suffice it to say, I think when buit you will have a funtional ride...

KiM
 
AussieJester said:
the rear, just IMHO, looks erm.."wrong"

shut up man LOL I like my mechano :lol: , especially with the polished inside alu tube in them as stiffners....

gtadmin said:
rodgah, looking really good mate ...

I know you got the triple trees from ChopperUS, but when I look for them I can't seem to find them. Would you mind putting up links for them, also your rims, tyres etc (things are hard to get in regional oz)

Thanks mate,
GT

GT.....not real hard to find them....under frontends > forks >........http://www.choppersus.com/store/category/5/30/Forks/

the rims and hubs are also from choppersus (along with extrawide BB and all related parts....), and I had them spoked and trued locally with 14gauge spokes. Tyres brakes etc are from chainreactioncycles.com.....in my opinion the only place to buy bicycle parts online. Free shipping over $400 order and fast!.

Appart from the spokes I really havnt purchased anything locally....except getting material for the frame.... everything else has been ordered.


recumpence said:
Pure artwork, Man!

Matt

needs some more CNC aluminium art work to finish it :wink: thanks man.
 
rodgah said:
AussieJester said:
the rear, just IMHO, looks erm.."wrong"
shut up man LOL I like my mechano :lol: , especially with the polished inside alu tube in them as stiffners....

HAHA yes yes WodGeR keep telling yourself that, you might eventually convince yourself its the truth :p :mrgreen:

Seriously mate, its one solid looking frame and will perform admirably ...

Now...more imporatntly! when are you going to show the lovely people of ES
your OTHER customised frame you just got back also :wink: I think you will get alot of favorable
response on that one too!! well, apart from the usual over thinkers that will bash the
fact it wasn't heat treated after the mods :roll: ... Thats the bike ima lookin forward
to seeing up and running the most Rodger! feeeel the power of the MoFo HoBO Turnigys :p
Bordtrackers are for old men and cripples like me HAHAHA j/k :wink:

Dont get to drunk tonight buddy and have fun :)

KiM
 
rodgah said:
AussieJester said:
your OTHER customised frame

Added pics of frame box :wink:

May I ask how much it cost you to have that battery box welded up? Its stainless steel I'm assuming, do you think it would cost more for Aluminium?

Thanks, Tom.
 
rodgah said:
...
GT.....not real hard to find them....under frontends > forks >........http://www.choppersus.com/store/category/5/30/Forks/

the rims and hubs are also from choppersus (along with extrawide BB and all related parts....), and I had them spoked and trued locally with 14gauge spokes. Tyres brakes etc are from chainreactioncycles.com.....in my opinion the only place to buy bicycle parts online. Free shipping over $400 order and fast!.
...
Thanks for the heads up. I write (or used to) web applications for a living and my expectations of how web shopping should be and how it actually is is way different. I can never find shit :shock:
 
rodgah said:
AussieJester said:
your OTHER customised frame

in good time....


Added pics of frame box :wink:

Your such a tease Rodger lol...dont make me up them first, i'll tell everyone its my new frame ROFL ;-P

KiM

P.s hope you feel better than I this morning, I feel off te wagon at the Casino last night got home at 5am wallet considerably lighter, damn I hate blackjack..lol
 
DALBYNATOR said:
much it cost you to have that battery box welded up?

Dont know an itemised price as I had alot of stuff done at the same time. Its aluminium. If I had to guess I would say there is about an hour to 1.5 hours labour and about $75 of material so probably worse case would be $200.

AussieJester said:
hope you feel better than I this morning,

spent all day in bed, felt like I had been ran over by a taxi....obviously a good night :lol:
 
Beautiful!! :shock: :shock: :D :D 8) 8)
 
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