CroBorg Commuter

[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.

[Alan B]

Next SoCal Bike Race at Grange - Saturday April 7th

Mark your Calendars.

Might have this thing built by then. Might be fun to try it on a track. Not really making a "race" bike but it should be faster than many even so.

[Alan B]

Tucson Death Race Cancelled for April 2012

Looks like no organizer for 2012

http://motorbicycling.com/f35/what-no-m ... 36084.html

[Alan B]

AVG Blade Helmet

Here is Kingfish's review thread on this helmet. Good pricing available now on this DOT rated helmet which is appropriate for this ebike and up to moped class use. Must be the end of the model year soon, driving prices down. Supply is also short, not all colors/sizes everywhere.

viewtopic.php?f=4&t=23862

[Alan B]

Schlumpf Speed Drive Installation

This install requires a special chamfering tool. I have confirmation that Ilia of ebikessf.com will do this. This is one tool I probably don't want to collect. He has a video on this installation process.

viewtopic.php?f=28&t=27355&p=400353&hilit=schlumpf+video#p400353

[Alan B]

Motorcycle/Moped Tire Installation Video



http://www.youtube.com/watch?v=AerHAYs435s

[Alan B]

On Headsets

Chris King headsets appear to be very good, used by racers. A bit pricey at $100+, maybe not needed on this project.

Cane Creek makes a range. Considering their 40.TR34 midrange model, about $50.

Headsets can be installed with makeshift tools, and it is not hard to turn a nice tool on the lathe. An installation mistake can ruin the head tube and essentially ruin the frame, so take care. The LBS can do it for you. I'll probably make a tool, or have Ilia do it when we are doing the bottom bracket.

[Alan B]

24 FET Controller from Lyen arrived. No frame yet, but it could arrive soon...

[Alan B]

Bits are flowing in.

Tires look nice. Michelin Gazelle 17x2.5.

No big boxes yet.

[Alan B]

I'd like to tell you that the big boxes arrived, but that would be better than reality. Good thing we're not anxious.

I checked the tracking numbers, one shows shipment on the expected date, but nothing else. The other must have a typo because it doesn't work. Not a big deal, those post office tracking numbers aren't too useful anyway.

The seat and tubes arrived, and the garage door opener. So we have another project to get done.

I should measure the tire diameter for interest. Here it is.

The Michelin Gazelle 2.5-17 inch tires measure 21-3/4 inches in diameter - unmounted.

What about tire weight?

A pair of them weighs 9 pounds 9 ounces.

And the seat:

Cloud 9 - 2 pounds 1 ounce.

And the tire tube:

A pair of Kenda tubes are 1 pound 3 ounces.

Tire Info from Sidewalls:

Michelin M62 Gazelle 2.5-17
Load Range B
Max Load 155 kg 342 pounds at 248 kPa 36 psi cold
2 polyamide plies
Canada and US codes only
DOT
W8XW 929T
1711
made in Thailand
43P Reinf
Tube Type
part 87-9389 sku 113658
there is a barcode sticker on the bead which I understand is the light side of the tire to go next to the valve stem

There are actually a bunch more things on the sidewall that don't look useful so I'll skip typing them all in. Amazing amount of info.

[Stevil_Knevil]

I really dig the tread pattern on the Gazelles!



Same tire.
Inflated height is a hair under 22" on my 1.20 rim.
Speed rating: P-Rated up to 93 MPH(!)

Yes, these will do nicely.

Edit: fixed (I measured from 1" and forgot to add it back Sorry!)

[Alan B]

That is a very handsome wheel. My tires look just like tat, minus the little rock. Sounds like they grow a bit under pressure. Good to know.

There are so many mold air relief nubs they'll probably lose an ounce or two when they wear off. Makes a porcupine look when new.

Question. A quick poll. The rims I'm looking at are black, as are the hubs. Black tires, rims and hubs call for ______ color spokes?

[Alan B]

Garage door opener installed. What a task. Took two days and four trips to the hardware store. Also need to sell the first opener I bought as it didn't fit, and really need a new garage door too. Maybe next month.

No real Greyborg progress but have been reading about bicycle dynamics. Some interesting contradictions there. Like higher center of gravity increasing stability.

[teklektik]

The rims I'm looking at are black, as are the hubs. Black tires, rims and hubs call for ______ color spokes?

It's a gestalt thing - what color are the frame and shell covers?

[Alan B]

Frame is back. Side covers to be determined. Seems like too much black.

[mr.electric]

For the most obvious bicycle look you want the side covers black and the frame tubes not black. With a brightly painted bicycle frame, people just see a bicycle flashing by as you ride. The factory made e motorcycles usually have a bright colored side panel or battery enclsure giving it a more defined motorcycle look.
These two are good examples of bicycle vs. Motorcycle. The pugsley has an understated battery enclosure. The enertia has an obvious battery.
Spoked wheels also add to the bicycle look.
The Grey Borg could go either way. The all black Grey Borg pictured would look more like a bicycle if the frame were painted white or another bright color.