Belt Driven Etek Trike

[Dirt-E-Dan]

Hey guys,

It's been a long time since I've posted on here and I've since been through a few electric bikes and now I'm onto a trike. I just wanted to post this on here to show everybody what I've been having fun riding around recently!

This project started about 2 years ago when I acquired a trike, an etek motor and a Sevcon Millipak controller. Those were the three constants of my build, and indecision helped prolong the project... but I think it made it that much better. The extra time was great for machining experience and with 3d modeling. These two programs helped me tremendously with my build, so I hope all of you enjoy! Also, us boys at FFR were wanting to make a more refined version of Tommy's (VRdubluv's) original etek trike using our new components and some Lipo batteries. Here are some other basic specs:

Etek Motor
Sevcon Millipak
Lipo batteries - 44.4v system at 25ah
FFR battery enclosure
Belt driven
Industry Nine front wheels
High Current Cycle Analyst
Magura twist throttle



Rear pulley that fits the splined disc brake adapter on a Shimano Saint hub.


I know i could shave a little weight, but this is the only place I got lazy on this project.


3d model of my motor plate in Autodesk Inventor.


Motor plate on the fixture in the CNC milling machine.


Drivetrain completed


It got MESSY in FFR's shop at 4am!


Cats love trikes!


The morning after completion in front of FFR!


Using her for her intended purposes.


In her most current form, sporting an 80t sprocket on the front so I pedal with her at 35 mph.

So far I'm seeing around 23 miles per charge on her when I'm driving around in sport mode and around 28 when I'm pedaling her in conservation mode. She has a top speed of about 38mph on a full charge and her acceleration is super smooth and powerful. The trike was finished on Thanksgiving day of 2011 and I'm up to about 650 miles on her without a hiccup!

I hope you all enjoy this! Let me hear what you all think!

Daniel

[Nehmo]

BTW, for those of you who don't already know FFR is a trike (tadpole arrangement) & bike production & sales company. I don't know what the initials stand for.

Regarding your rear pulley: Is it meant for a Gates belt? Are the valley profiles circular?

And is there a freewheel anywhere in the drive system?

[Dirt-E-Dan]

The pulleys are for 8mm HTD belts. It's not quite a circular valley profile.

The Etek motor with the Sevcon Millipak controller gives the option of running regenerative braking and I have mine set to regenerate to 30% of it's capability so that I can still somewhat roll up to a stop without it stopping me too quickly. A freewheeling belt drive system, in my opinion, would be ideal for this setup though.

[biohazardman]

Nice werq on the bike love the belt pulley and motor mount. Big enough motor for sure it should not have to werq to hard so last forever. Thanks for the post

[lostrack]

That's bloody cool. NICE WORK!
Are you really just towing a mountain bike? I can imagine the faces of passing mountainbikers. MAybe you could offer a towing service.

I'm interested to hear how the mars motor is going - I get the impression they have rediculous power, what's it like?

There was the 8KW recumbent that was out accelerating cars. IS that the goal for this system?

[Rouckie]

I'm interested in the way you made the htd sprocket. What cutter did you use and where can I buy one? I made one with a ball nose end mill and 4th axis, but it is time consuming...

[Dirt-E-Dan]

I get the most confused and funniest looks from people when I'm towing my bike down the road! I have the max amperage on the controller set to 200amps right now so she has great power. Her acceleration is quick and very smooth off the line. The torque is incredible and I love being able to start from a stop. It would be a great candidate for a pedicab service in a city.

Our goal for the trike was actually to build a more utility ready trike so I can do things like tow a mountain bike or tow a trailer. The fact that I can beat unsuspecting people off the line at traffic lights is just a bonus!

We turned the pulley blank to the right shape on the CNC lathe then manually milled the hole patterns in the part. After that I sent it to a local company (near Charlotte, NC) to be hobbed. They have an 8mm HTD pulley hob so I just told them how many teeth and they did two pulleys for me at $18 ea. They also made the drive pulley from scratch for me as well. Our shop has a hobbing machine, but the hobs are kind of expensive!

[dontsendbubbamail]

Daniel,

That is a good looking trike. I bet this is what you texted me about a while back. The text was grabbled and I have been a slacker boy in getting back to you. I need to go up to Fletcher soon to check on my father’s house. Maybe we can do a road trip together and visit Tommy. I want to see his shop.

Bubba

[grindz145]

Hah I always love the bicycle-tow setup That thing must move a little eh?

[Dirt-E-Dan]

Thanks Bubba! I think it is the one I texted you about a little while back. Let's meet up sometime so you can ride this thing! Also, we can definitely make a little trip up to Fletcher sometime. I go all of the time. The shop is lookin' nice!

Grindz, I like your tow setup! My center of gravity is a little high, so I can feel it pulling me around a little. I can't wait to use it more when it warms up a little and the days are longer!

[GITech]

Ok, I'm jealous!

Are you in canada?

Later,
Jay

[dumbass]

Great lookin setup.......Can you tell me how many teeth are on each pulley? And do you know the max RPM of the motor or the RPM per volt? IT also looks like the motor has a fairly small shaft. Do you remember the size?

Thanks,

Bob

[nikos7]

Beautiful machining...how did you machine the teeth on your rear pulley? any pics on your setup?

Thanks

[Dirt-E-Dan]

Sorry for not responding for a few days! I'm running a 15t to an 80t, 8mm htd pitch belt drive. I don't have the exact specs on the motor, but based on the top speed and gearing, I think it is around 60rpm/volt. It has a maximum RPM of about 2600 rpms I believe. The motor actually has beastly shaft on it. It's 7/8" with a 3/16" keyway.

nikos,

Thanks! I had a local company use their gear hobbing machine with an 8mm HTD pulley hob to machine the teeth. If you're unfamiliar with a gear hobbing machine, I'm sure there are videos on Youtube.

[Dirt-E-Dan]

Hooray for breaking 1,000 miles!

[Kin]

I'm not sure if it's much of a faux pas to bump slightly old threads, but this looks sweet! I hope you'll update things if you have any new news!

How did you feel about the heavy weight of this motor verse running two 80100? [My guess is two 80-100s should offer similar power, but maybe i'm underestimating the extent to which this bigger mass can take very large bursts].

[neptronix]

Need videos of it in action!!!

[sn0wchyld]

I'm not sure if it's much of a faux pas to bump slightly old threads, but this looks sweet! I hope you'll update things if you have any new news!

How did you feel about the heavy weight of this motor verse running two 80100? [My guess is two 80-100s should offer similar power, but maybe i'm underestimating the extent to which this bigger mass can take very large bursts].

I'd say this'd handle 9kw much easier than a twin 80100. Also requires less reduction... to get ~5kw out of a 80100 reliably you need to spin it, FAST. ie ~9krpm. that means it'll likely need about 20:1 reduction, or a bit less for trike size wheels. pretty much impossible with 1 stage. this is probably quieter too. Still... im curious how it'd compare to a twin 80100 too. maybe a triple 80100 could beat it?

Need videos of it in action!!!

+1.
+10000000000000000000000000000000000000000000



edit
just a thought, how about useing a 2 stage reduction from the wheel to your pedals? that way you could use more 'normal' sized chain rings?

[Dirt-E-Dan]

Hey guys, sorry for the late response! My notifications are messed up and I didn't realize that you all have been posting. I'm not sure how the power of this thing compares to those two motors. Are you all talking about the 80-100 Turnigy motors? The biggest benefit of this motor is the ability to start from a stop. Weight while riding has never been an issue. Carrying it up 9 stairs to get it inside of my house is the only issue I have with the weight!

I thought about going with the Schlumpf drive (planetary gear set) for my crankset, but decided against it because of cost. I don't need the low speed pedaling ability since i can use the motor from a dead stop. It basically is only there for me to pedal between roughly 12 and 37mph.

She's a silent beauty! She makes some alien-like noises when it starts to regen a little, but it's a very quiet ride overall.

I guess I answered all of your questions except for the "new news." I have started a new project that i'm not going to reveal just yet, but I am now going to sell this trike to help fund it. I won't put a price on this post, but if anybody is serious about wanting this utility trike, please send me a personal message!

It hurts to say this because I've become very fond of this trike, but to officially state it, she is now FOR SALE...... She is great for a solid 20-25 miles per charge at full speed (and fun acceleration) and a riding style of around 23mph, i've seen about 35 miles per charge. A great little vehicle! I'm in NC and can Freight this or deliver(if you're within 500ish miles) at the buyer's expense.

I know this isn't the used forum, but I figured this thread would be the best place to post this. Please let me know if you are interested!

Thanks,

Daniel

[Dirt-E-Dan]

Oh yea, I've seen her pull about 7000 watts under full acceleration. The motor is rated for 4500 watts continuous and 11000 watts peak. She's a beast!

[neptronix]

Post your ad, including pictures, and location, in the used section for sure.

But get video first!!!!

[Kin]

ahHHHHHHHHHH damn, if I could afford to buy that. It's even in the right location. One day hopefully I'll make one, but it's not going to be nearly as nice as the FFR trike.

[Dirt-E-Dan]

This trike has now been posted in the used section with a few mor pics + a video!

[Parkie]

Please forgive a rookie question but the pictures do not show how our pedel sprocket is connected to the drive system. is there a picture that would explain Please?

[amberwolf]

If the pedals are even hooked up then they just run thru the normal regular drivetrain. The motor is on the other side.