CroBorg Commuter

[Alan B]

More info on Gatorbrakes:

viewtopic.php?f=3&t=24827 Hal testing Gatorbrakes

Shucks, even I posted in that thread. That was a while ago.

Hal recommends the 6 or 8 piston Gatorbrakes

Wondering what the Stealth Bomber and Fighter use?

Stealth Uses 6 piston Gatorbrakes according to one posting (edit - apparently 8 piston are an option)

viewtopic.php?f=3&t=34313

MadRhino suggests Hope Tech V2 with floating vented disc for the front

Interesting note - Magura has hydraulic switches - this could be useful for regen or even stop lights...

viewtopic.php?f=3&t=33869 how long do pads last

[Alan B]

Motor Controller

Cromotor users are split between 18 FET and 24 FET controllers with the 18 FET being a bit more common.

I'm leaning toward running the 24 FET fairly stock rather than modding an 18 FET. Either will fit in the 'Borg chassis. The 24 FET has more thermal mass and can handle the heat better.

With 18S Lipo the bus voltage is around 70V so 100A is 7KW. That is well within the Cromotor's capability.

Lyen 244110 Controller Selected

Update - Lyen 244110 Controller Ordered - should have in a couple of weeks or so. About the same time as the frame.


Note - it is less than 1.5 months to the Mega Monster Enduro Race. Lyen entered last year, and this year a number of ES folks might be there:

viewtopic.php?f=3&t=35124 Rollcall for the upcoming 2012 Race

http://megamonster.lowkeyhillclimbs.com/2012/ The 2012 Race website

viewtopic.php?f=3&t=25266 Lyen's 2011 Race Experience thread

But will the 'Borg be ready in time?

[Alan B]

No Borg by Mega race time. Not going to rush it, not going to be ready. Have to use the mountain ebike if I go.

Wheel builds set up for mid February. 17" Aluminum moped rims.

[Alan B]

24 FET Controller built and in the mail.

Wheel builds lined up.

Torque plate build lined up.

Working on steering component selection.

If six piston Gatorbrakes are good enough for Stealth Bomber are they good enough for Greyborg? Or do we need eight??

[Accountant]

If six piston Gatorbrakes are good enough for Stealth Bomber are they good enough for Greyborg? Or do we need eight??[/quote]

They are good enought, but Stealth is also offering 8 pistons upgrade.

Only 8 piston calipers can be bought for double caliper version.

6 piston caliper for right side disc do not exsist.


You can never have too much stopping power, and modulation is much better with 2 discs.

[Stevil_Knevil]

Hey Alan,

I am running 6 piston Gators with 203mm rotors on my 'Borg..



..one finger on each brake lever hauls it down from 40+ MPH quickly and predictably, with good modulation and disregardable fade. Bear in mind - this is with a 20S 1P LiPO pack and my spindly 145 pound self.

Dual 8 pots out front would be unfknblvable!

[Alan B]

If six piston Gatorbrakes are good enough for Stealth Bomber are they good enough for Greyborg? Or do we need eight??

They are good enought, but Stealth is also offering 8 pistons upgrade.

Only 8 piston calipers can be bought for double caliper version.

6 piston caliper for right side disc do not exsist.


You can never have too much stopping power, and modulation is much better with 2 discs.

OK, Good to know.

Penciling in 8 caliper 203mm Gatorbrakes for the front and Six for the rear.

Not sure where to get those. Not easy to find a website that sells them.

Having a mix of sizes may not be great. Might be better to use same both front and rear?

[Accountant]

I have them all.

4, 6 or 8 calipers.

8 calipers single or dual (left and right).

check here :

[Alan B]

Cost and shipping? Please send in PM, thanks.

It would be good if the information was all in one place on what is available. I find fragments here and there, and the build parts list on page 4 has errors that should be fixed. I would suggest keeping a full list somewhere, perhaps on page 1 of the for sale thread, and update it as it changes.

[Alan B]

Stevil,

Those white covers are really something. What are you planning to do for a color scheme?

[Accountant]

Stevil,

Those white covers are really something. What are you planning to do for a color scheme?

Material used is excelent for easy spraypainting.

Havent you noticed my Green canopies, and black ones ?

Web page and web shop will be on soon.

[Tom Tom]

Web page and web shop will be on soon.

Looking forward to it. Its a real pain in the arse reading thru the threads for info on the greyborg.

Any news on a North American Distributor?

[Alan B]

Color Scheme

I have looked at all the threads and sites I can find on the Greyborg and seen green, black and white color canopies. I have wondered about doing something a bit different, perhaps with more than one color. But I'm not decided on any plan. Looking for suggestions to consider.

The rims I'm probably going to get are black. Spokes can be black or bare. Frame tubes are black. Forks are a tan color if I remember right. Motor is black.

Any clever ideas out there?

[MadRhino]

Chose a theme colour to complement the black, and make a design of that coulour and black for the canopy.
For one of my bikes that is black, I chose red. Then, selecting red accessories and components, adding some striping, all that makes a neat finished look.

[Stevil_Knevil]

queuing from the Borg theme..
http://en.memory-alpha.org/wiki/Borg_drone
..I considered incorporating some of the exo-plating designs, with a few embedded RGB LEDs (to indicate SOC) into the bodywork.

I admit it, I am a SciFi geek

Been holding off since I may need to cut a few holes for charge and balance headers. In the mean time, I have been running without the upper right canopy for easy access to swap packs and monitor the controller temperature -which gets pretty warm and likes some cool air flowing over it. The open, visceral appearance of the controller, batteries and wiring in there has gotten more than a few, "That looks like the terminator after he got bashed-up.." remarks from folks I encounter, and yes, it kinda' does!

The monochromatic, white on black has grown on me. It reminds me of a stormtrooper.

[Alan B]

Thanks for the comments. I'll have to work more on color scheme.

Controller hasn't arrived but probably will in a day or so. Lyen is not far from me and it was shipped. He even did a video of the testing. Amazing.

The frame is about a week out. Theoretically, tracking is not very accurate.

Ordered some Michelin Gazelles in 2.5-17, tubes and rim tape. Also a garage door opener to make it easier to get the ebikes in and out. Also got a new Makita air compressor that is amazingly quiet. Good for the shop and the occasional bike tire needing some air.

Was researching freewheels again. Seems that the White Industries is the best, but noisy - clicks louder and higher frequency. Shimano generally rates second best, is much cheaper, and can be silent. The White Industries never break but Shimano's occasionally do. So what do folks use on their singlespeed hubmotors? Wonder what's on the Stealth bikes?

Also looking for comments and recommendations on headsets, stems and handlebars.

[cassschr1]

Lets hear about the TA please

[Alan B]

On the Torque Arms I'm working on a plan with a local machinist, but we won't start in earnest until the frame is in hand.

Helmet Upgrade - ordered AVG Blade in blue/white. I think this bike is going to be black and blue. I have some nice Krylon Fusion in Safety/Patriotic Blue that looks nice. Maybe that's a bit dark though.

So any comments on freewheels, headsets, stems or handlebars? Oatnet suggested an adjustable stem. Is it okay to run an adjustable stem all the t ime, or is this just to get started and then change to a fixed one?

I also saw a Sheldon Brown article suggesting a clamp collar instead of spacers at the top of the headset, and then keep the steerer tube full length and get some extra handlebar height that way. Can always cut it down later when things are better understood.

How difficult is headset bearing race installation? They mention special tools to keep it aligned. Should I have that done or turn some one-use tools from PVC pipe, or would that even work? I could use aluminum rod instead which should work?? Just need to turn a shoulder?? Make it long enough to go all the way through and then with both cups in place to guide the rod tap them in?? What have others been doing?

Thanks in advance for your comments.

[Alan B]

Thread on DIY bike stuff including headset installation:

viewtopic.php?f=28&t=8485

[briangv99]

Hi Alan, I am building a Warp with cromotor too. I found the shoulder on the axle on the freewheel side does not protrude past the freewheel threads, it sits level with them. I was going to use a Shimano freewheel that I already had, but the freewheel doesn't thread through, it has a collar, meaning a spacer on the axle would be needed and the frame dropout stretched further. I'm now using a Dicta FW that threads all the way through and lets me use no spacer on the freewheel side.

The disc brake side is a different story, to fit a disc rotor and clear the wiring, I've built a 10mm thick c shaped spacer, the wiring now just barely clears the disc rotor and can jt ex around the dropout. There was no getting past stretching the frame out to fit the spacer. If you're not fitting a rear disc and using regen for a brake, I'd go with the Shimano FW for near silent running and a spacer.

[Alan B]

More good internet sites on Bicycle maintenance and building:

http://sheldonbrown.com/

http://bicycletutor.com/

DIY Headset tools and procedures:

http://forums.mtbr.com/tooltime/mkiii-h ... 30069.html

DIY Wheel Building:

http://miketechinfo.com/new-tech-wheels-tires.htm

Installing Moped/Motorcycle Tires:

http://www.dansmc.com/tires1.htm


Feedback:

Thanks briangv99 for the comments. Have a lathe here, can make custom spacers.

Would the Shimano thread all the way down on the Cromotor, or did it run out of threads before it was fully "on"?

How is the "Chain Line" and what crank are you using?

[briangv99]

The Shimano runs out of thread, so sticks out a bit, the dicta screws all the way down. Cranks I'm using will be back up only with I tiny 21 tooth gear from a BMX trials bike. Not sure about chain line yet Oi Po

[motorino magnet]

Hello

Thank-you for this thread.Its like getting a bunch of experts to order your new car for you.Spent at least a hundred hours running around the forum and the greybeard is the easiest for a first build,i think.

I have a scooter stye for highway use and now i want something for trails and off road fun to legally go on the trail around me here in Niagara Falls Ontario.

The journey is hallways better than the destination-unless your already there.

How much- roughly- do you think you will have all in for everything,including shipping to the US?
Inquiring new minds would like to know the damage to the pocket book-aka-my wife!I told her it would only be about 5 grand
I have almost got her convinced since borrowed money is free and the world is coming to an end anyway ,some folks think.

She wants to know if we can get a seat like on the Charley to ride double-if she can hang on tight enough.

And I think your color scheme should be a patriotic red,white and blue-since mine will e sporting a big red maple-leaf on the white background with a nice little hood scoop.

Too much fun !

Cheers

[Alan B]

Thanks for your comments.

My present estimate is the same - 5K. It depends on battery capacity and chemistry. It could be a K or more either way.

[Alan B]

You could probably do it for 3K, perhaps less if you were careful and skipped some of the optional things. Use bike tires and rims, skip dual brakes, downsize controller and battery, use standard single speed crank, maybe a lower end fork. Save even more by using lower power/cost motor. So the cost can vary by more than a 2:1 ratio. Full up with pretty near all options it is about half of a Stealth Bomber in cost. The Bomber has that transmission and is very tough, but the 'Borg will carry more battery and should be a bit lighter. They are similar but different in many ways.

One thing about building a Greyborg - you will learn a lot. Short of welding a frame or winding a motor, you will learn most everything about bikes and ebikes, aside from what you hire out.