Re-winding a hubmotor

Electric Motors and Controllers

Re: Re-winding a hubmotor

Postby Andje » Thu Feb 23, 2012 9:28 am

So if you had been charging say 50$ an hour at a massive E-S discount on your labour, the commissioner would be looking at owing you 4500$ for your time, and you'd be out a further 3500$ of labour for screwing up. Kind of puts the effort in perspective :P.
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Re: Re-winding a hubmotor

Postby liveforphysics » Thu Feb 23, 2012 1:39 pm

You've got two sets of magic pie side-covers. One set needs to be turned into swiss-cheese badly, the more airflow you can get across those coils, the longer and happier life it's going to have.
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Re: Re-winding a hubmotor

Postby Farfle » Thu Feb 23, 2012 1:58 pm

One set will be set up for air cooling, and one set will be set up for a semi-bath oil cooling.
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Re: Re-winding a hubmotor

Postby liveforphysics » Thu Feb 23, 2012 2:11 pm

Farfle wrote:One set will be set up for air cooling, and one set will be set up for a semi-bath oil cooling.


Perfect! :-)
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Re: Re-winding a hubmotor

Postby Microbatman » Thu Feb 23, 2012 5:05 pm

Great Job!!!
Brave partner holding the axel like that.
Glad he did not make a short sleeve shirt in the testing process.
Bike looks even better on vid than it does in still pics.
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Re: Re-winding a hubmotor

Postby XLR8 » Thu Feb 23, 2012 6:39 pm

Absolutely fabulous job. Well done.
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Re: Re-winding a hubmotor

Postby stinkler » Fri Feb 24, 2012 6:50 pm

That is a BEAST! Better post some riding vids soon or there is goin g to be a riot.
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Re: Re-winding a hubmotor

Postby amberwolf » Fri Feb 24, 2012 7:24 pm

That's a heck of a test!

I am definitely looking forward to the laced-up ride videos. :)
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Re: Re-winding a hubmotor

Postby Farfle » Fri Feb 24, 2012 8:35 pm

Uurg! The ultramotor spokes we had at the shop were too short.. Like 3mm too short, they would lace up, but it wasn't confidence inspiring. So, I challenged the LBS to see how fast they could do 36 100mm spokes :lol:
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Peak power in : 420A at 87v
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Re: Re-winding a hubmotor

Postby amberwolf » Fri Feb 24, 2012 9:41 pm

Hopefully you dind't tell them waht it was for, or you will probably never get them. ;)
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Re: Re-winding a hubmotor

Postby bigmoose » Fri Feb 24, 2012 9:58 pm

Sure ran smooth!! Did I miss how you are clamping your axle on the bike? ... or are two vices in order? :P
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Re: Re-winding a hubmotor

Postby Farfle » Sat Feb 25, 2012 5:45 am

The droupouts are a special creation of mine, ill get some pics of them when im at the shop next. In the meantime, I have a video of it running on the bike that shows the dropouts a little bit. And no aw, I never tell them what it's for. If the guy asks why I want super short spokes, I just say that i'm relacing a wheel on a kids bike.
The race bike:
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Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


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Re: Re-winding a hubmotor

Postby Farfle » Sat Feb 25, 2012 12:00 pm

sorry guys, no riding video yet, how bout a walkaround?

The race bike:
24s5p 50c nano tech
Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


Team Farfle blog!! http://www.farfleselectrics.blogspot.com
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Re: Re-winding a hubmotor

Postby Alan B » Sat Feb 25, 2012 12:06 pm

Very nice!

Any idea what that 'clicking' is?
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Re: Re-winding a hubmotor

Postby Farfle » Sat Feb 25, 2012 12:26 pm

Alan B wrote:Very nice!

Any idea what that 'clicking' is?


It didnt do it before i varnished the stator, and now it does, so im guessing that its just the dang varnish rubbing on the mags. It has self-clearanced quite a bit, and im hoping that with some more miles that it goes away, if it doesn't I'll pop it open and sand it.
The race bike:
24s5p 50c nano tech
Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


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Re: Re-winding a hubmotor

Postby ohzee » Sat Feb 25, 2012 12:28 pm

Looking good.. I like how the braided wires look as well.

Can't wait for that puppy to be laced up.
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Re: Re-winding a hubmotor

Postby zombiess » Sat Feb 25, 2012 12:59 pm

ohzee wrote:Looking good.. I like how the braided wires look as well.

Can't wait for that puppy to be laced up.


Not only do they look good, they reduce the overall induced inductance into the hall wires running near them because they are no longer parallel. At least that's what Farfle likes to tell me, but I know he just really loves to braid :mrgreen:
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Re: Re-winding a hubmotor

Postby nicobie » Sat Feb 25, 2012 1:25 pm

Awesome dropouts! I can't see any spinout problems in your future.
Image

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Re: Re-winding a hubmotor

Postby stinkler » Sat Feb 25, 2012 3:07 pm

Good lord that thing is going to rip.
What size rim are you thinking for that fat bastard?
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Re: Re-winding a hubmotor

Postby gensem » Sat Feb 25, 2012 9:49 pm

Alan B wrote:Very nice!

Any idea what that 'clicking' is?



the noise is very much alike the one I have... and im almost sure its the hub bearing...
will WOT alot to see if it goes away... dont really wanna open it.
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Re: Re-winding a hubmotor

Postby Farfle » Sat Feb 25, 2012 9:57 pm

heres some pics of the dropouts, not welded in yet:

Image

Image

Image

Image
The race bike:
24s5p 50c nano tech
Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


Team Farfle blog!! http://www.farfleselectrics.blogspot.com
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Re: Re-winding a hubmotor

Postby bigmoose » Sat Feb 25, 2012 10:01 pm

Farfle, I sure like your dropout solution! Absolutely, positively solved it. Plenty of wire room and NO possibility of rotation.
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Re: Re-winding a hubmotor

Postby liveforphysics » Sat Feb 25, 2012 10:29 pm

Farfle, you are a rockstar. Love it!
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My bicycle completes the standing quarter mile in 11.502seconds at 110.56mph.

Giving my time to the electric revolution is done with pleasure. It is no longer fashionable to spit carcinogenic combustion by products in peoples faces as a part of sating daily transport.

Every post is in honor to the free idea exchange that Justin le preserved to grow with an amazingly high quality content in what is the living bleeding edge of LEV development.
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Re: Re-winding a hubmotor

Postby Arlo1 » Sat Feb 25, 2012 11:16 pm

Yup awesome dude!
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Re: Re-winding a hubmotor

Postby parabellum » Sun Feb 26, 2012 9:15 am

Farfle, this monster is bomb proof in every direction. If this is the result of simple "Re-winding a hubmotor", your potential must be inexhaustible. Awesome work.
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