The New EZip "StepThrough"

[docnjoj]

Hey folks those motors and gearboxes used to make a terrible racket with straight cut steel gears. Did they (Currie) change something to make them quiet?????
otherDoc

[DrkAngel]

Just pulled out my 2008 Trailz, for the weekend.
And yes, I almost cringed at the motor noise.
Speed and acceleration seemed better tho, top speed definitely was!
Of course that might be due to the oem "smooth" tires at 70lb, vs the 2.125 "comfy" tires at 40lb.

Sounds like a drill, with bad bearings, inside a tin can ... till it gets up to 20mph, then actually sounds "nice". Makes me want to try it at 36v, just to hear the sound.

The 2009, on the other hand, is nearly silent!
Can't even hear it with 15mph wind passing my ears!

I decided to standardize all the motors-wheels by inserting "Deans"- "T plug" connectors near the motor. Makes all rear end work much faster & simpler. Could probably swap noisy motor-wheel onto 36v ezip in 5 minutes.

[DrkAngel]

I decided to standardize all the motors-wheels by inserting "Deans"- "T plug" connectors near the motor. Makes all rear end work much faster & simpler. Could probably swap noisy motor-wheel onto 36v ezip in 5 minutes.

Actually, I use a variation of the "Dean's Plug".
The variation I use has the same 100amp rating, but adds a gripping texture, that allows separating the connector via gripping the connector, rather than needing to pull the wires to get a grip.

100amp gold plated quick connect

T-Plug.jpg (43.46 KiB) Viewed 2347 times

I can recommend this source:
New Red Nylon T-plug Male/Female 5 Pairs(10 pcs)- $3.99 + $2 shipping
Fast shipping & confirmed stable under soldering temperature.

[DrkAngel]

I decided to turn my StepThrough into my comfort cruiser.
I did, modify the big chrome fender to fit the front wheel, but would have had to majorly crush and mangle to get the rear installed, decided to save it for some other bike.



I removed the oem seat and installed a big comfy saddle. A vast improvement, for my extended cruisings.
Problem is, when I fully lowered the seat, for cruising stance, it sat me fully upright, placing undue weight on the rear wheel. I broke 1 spoke while carrying a 70lb load on rear rack.
So I decided to:
1. Stop carrying heavy loads
2. Add a suspension post - to cushion the impact weight, of my personal 200lb
Problem - Could not find anyone who sells an 28.6mm suspension post
Solution - 27.2mm suspension post - $11 & 27.2 - 28.6mm Seat Tube Adapter - AU $3.99]

The result:
Pure bliss ... I can cruise for hours. Every little bump or blacktop "patch" that assaulted my aging butt & back ... seems to have disappeared.
I even did a tour of the old brick streets ... they became a scenic pleasure ... rather than a jolting annoyance ...



No, I'm not totally lazy!
It takes about 5 seconds to adjust seat height, for "proper" pedal-assist.

I've never been satisfied with the oem lubricant on suspension posts, or front forks, I was lucky enough to find some SKIL SUPER-DUTY LUBRICANT no.252. This was designed for the gear reduction motors of the SKIL power saws, of decades past, works better than anything else I've run into. A very light-weight grease consistency.

[DrkAngel]

I had been running my EZip Trailz, testing my homemade Lipo pack.
Top speed 23 mph, smooth "road" tires.
But as the Fall approaches, I've turned to my "Stepthrough" as a more comfortable-casual cruiser.
20mph, quieter motor, upright posture, and better all-around tires seem much better suited for my scenic touring.
Gotta get that done, before the snow flies ...

I've put more than 1000 miles on my "homemade" recycled Lipo pack!

[DrkAngel]

... as the Fall approaches, I've turned to my "Stepthrough" as a more comfortable-casual cruiser.
20mph, quieter motor, upright posture, and better all-around tires seem much better suited for my scenic touring.
Gotta get that done, before the snow flies ...

My "Scenic Cruising" includes "The Allegheny River Valley Trail" system.
The Trail is a pleasant meandering through a mixed forest area combined with wide open views of the valleys surrounding hills.
The local Fall foliage is approaching full color, and this weekend is expected to be beautifully sunny and warm, mid - 70s.

This looks to be an enjoyable weekend for entering the 100 Mile Club.
I've probably been there, a while, but never kept track of daily mileage.
I have 3 - 25.9v packs ready to go, a 26ah Lipo & 2 - 31.2ah Li-ion.
25.9V x 88.4ah = 2.29kWh - Almost 150 miles capability in economy mode.

I could make 100 miles in under 5 hours with my Trailz, but 6 hours on my comfort cruiser sounds much more enjoyable ...

[DrkAngel]

I just passed 2000 miles, with my "Stepthrough", and thought I would post my review-impressions.

Ist off, I am satisfied.
The quiet, comfortable, ride is an nice alternative to my speed-power enhanced EZips.
Also, the stepthrough feature is almost a necessity, when carrying a load on the rack.

2 problems:

1. The battery drops into the rack and contacts with 2 brass(?) contacts.
Both of these sets of contacts melted the plastic retainers, that allowed the brass contacts to move freely.
This resulted in poor, but then, damaging contact.
I resolved the fault, by replacing, with the contacts, from a 2008 Mountain Trailz, which had been modified, for 37V.
I've never had a problem with the 2008 MT pack contacts.
Alternately, the 2008 Trailz, had cupped stainless contacts, which also suffered 1 failure.
From my first EZip, contacts seemed to be a problem, they got "dirty" and provided poor connection.
The pack rattled in the rack, with brief power loss and lock damage.
I bent-squeezed the rack slightly, with a tourniquet, so as to hold the pack tightly, and added a 1/2" bungee, around the rack, which also held the pack-packs firmly down. I also added "heatsink" conductive silicon grease, to the contacts to help maintain contact and prevent contact degradation.

Contacts.JPG (12.88 KiB) Viewed 720 times

2. Broken spokes!
I had about 4 instances!
I even resorted to buying 12ga spokes, not installed yet, a Winter project, may require drilling ...

Strangely ... the breaks were on the pedal sprocket side?
I say strangely, because all the 2008 Trailz's always suffered broken spokes on the motor side?

I didn't realize the significance, till I laced a new hub into a wheel.
After careful consideration as to directional torque and how the spokes were supported in the hub flange, I determined that the motor & pedal torque should be sustained by spokes with the elbows turned outward.
After looking at my other EZips, I was able to confirm that the spokes were breaking because the torqued spokes had their elbows turned inward!

A picture of my 2008 EZip MT w/16 mod.
As you can see, the inward turned elbows are poorly suited to survive torque.

Stressed MT.JPG (34.39 KiB) Viewed 1220 times

14ga spokes might work satisfactorily with the EZips, if properly directionalized!

Well it's about time for me to pack away the Stepthrough, and put my Winter EZip back on the road.
Configuring my pack heaters ... now.


Oh!
One last thing!
Whitewalls NOT recommended for the EZips!
The alloy wheels, combined with brake residue, road grime etc, creates some grungy, nasty black-gray staining.

[DrkAngel]

Alternate option for broken spokes is a better hub.
I found a couple of these on clearance ... all gone now.

NHSpk.JPG (32.69 KiB) Viewed 726 times

Compared to the EZip OEM!

[DrkAngel]

I've been rebuilding EZip hubs ...
One of the best-worst points is that the hub flanges need no drilling to fit 12ga spokes. (2008 Mountain Trailz)
Which means :
1. No drilling on hubs
2. Holes were too big to properly support the oem 14ga spokes!

The wheel does require redrilling, with 3/16" bit
Will (severely) road test, before upgrading 2nd wheel to 12ga.

I also built 2 wheels using aftermarket, eZip compatible, hubs. (No longer, or unknown, availability)
1 as an EZip replacement for bad hub, replaced the QR axle with the oem EZips.
The other, a QR for my 700C Haro.
Sadly the motor mounting brackets, I got from TNCScooters last year, will not work, alignment is way, way off!
Guess I'll have to get 1, or 2, from EZipUSA.com.
Or, I could have a local machine shop make up a lighter-smaller bracket, to my pattern?

Not worried yet, all projects are for Spring.

[bluegoatwoods]

Hello DrkAngel,

Thanks for all of your detailed posts, giving near-microscopic views of the e-zip Trailz.

I own a 2008 men's model. I'm mostly happy with it,though I'm not yet convinced that I'd rather ride it than my plain old pedal bicycle. Right now my chain-stays seem to have gotten out of alignment; I'm having tire rubbing issues. I wish the dropouts weren't vertical. I'm gonna have to figure out how to straighten it.

I also had my primary battery contact deteriorate, then melt. Seems to be a weak point. I've rewired and that's no longer an issue for me.

Those lithium ion battery packs you make from laptop batteries are very tempting. I don't think I'll try it, though, until I get a better understanding of safe charging, maintenance and use technipues.

All in all, your posts tend to help me understand the bike as a whole, possible weaknesses and possible remedies more quickly than I'd likely have figured out on my own.

[DrkAngel]

Broken Spokes - Solutions!
Multiple solutions for the EZip - IZip broken spokes problems!