Custom Ebike Parts [Was custom X5 axles]

[Farfle]

Here's a shot of a modified stator, You can see the motor end of the wiring loom on the left. Sorry for the bad picture, it was taken while in a hurry to get the shop cleaned to start production of some new axles.

[Farfle]

A few pictures of parts fabricated for another ES member: 1/4" plate, hardened clamping dropouts with grade 8 hardware. Custom built to fit a Norco Sasquatch with a rear rack $45.

[RallySTX]

I think the pics are ok. Is that 1/4 inch stock you used for those dropouts? I should be ready to buy a 9 inch X5 axle soon.
Brian L.

[Farfle]

I think the pics are ok. Is that 1/4 inch stock you used for those dropouts? I should be ready to buy a 9 inch X5 axle soon.
Brian L.

yes, they are 1/4" plate, and The Shippable X5 axles are going to have to wait until I get the tooling to do the center knurled friction-fit portions of the axles. Until I get that the only thing I can do is modify existing axles .

[mikebikerad]

I'll send you my motor. Pm sent!

[Farfle]

Custom Axles will be available shortly! Knurling equipment is on its way. Does anybody have a sacrificial X5 that they can donate or sell to me for a reduced price? Preferably burnt up, with no rim and no wire. I will be using it to do some real world tests on how strong these axles are compared to the standard X5 axles, and how they can be made better.

[Farfle]

Here are some pictures of a pair of HX motors done up with high-quality 10 Awg wire and upgraded axles for a customer here on the Forums:

[wojtek]

Here are some pictures of a pair of HX motors done up with high-quality 10 Awg wire and upgraded axles for a customer here on the Forums:

great job! have you also find a way to "waterproof" the inside of the motor after making the holes? to prevent from rust? any spray or something?

[oatnet]

Here are some pictures of a pair of HX motors done up with high-quality 10 Awg wire and upgraded axles for a customer here on the Forums:

great job! have you also find a way to "waterproof" the inside of the motor after making the holes? to prevent from rust? any spray or something?

You not only copied the initial post in your reply, but copied all the pictures too, which clutters the thread.

At the factory, the windings of electric motors are covered in a varnish which "waterproofs" them, the rest is not waterproof. There isn't really anything Farfle can do or spray to waterproof the rest, and it isn't really necessary. Drilling holes in the side covers is a standard practice for a hot-rod motor (nicely executed here by farfle), and there are many threads about it that can give you insight to the practice, just use the search box.

-JD

[wojtek]

apologies - i have sorted it out.

I am wondering if xlyte with holes is a good idea for offroad riding. Quite a lot of dust, little rocks ect...

[oatnet]

apologies - i have sorted it out.

I am wondering if xlyte with holes is a good idea for offroad riding. Quite a lot of dust, little rocks ect...

Methods has posted several times that he didn't have a problem with dust etc on trails. The search box is your friend! There are several threads that discuss this common, basic modification, so the search engine can get you an answer from a how-to thread without knocking a for-sale thread off-topic.

Meanwhile, back at the ranch... Farfle was machining some nice mods...

[Farfle]

Meanwhile, back at the ranch... Farfle was machining some nice mods...

9C sidecovers for an ES member, milled with slots in the new jig, oddly enough the bolt pattern is identical to the HX series xtalyte motors only found that out after making a second identical jig :



The bit got a "flake" stuck to it and caused a small disturbance in the force it only succeeded in scratching the paint tho .




But Anywho down to business, assuming the deal goes thru, the first 6 lucky ES members that send me a PM can reserve one of three 5404s or three 5403s done up with all the mods. Here is some info on this bad-arse modded motor:

motor core cost: TBD

Axle mods, Bigger/smoothed wire groove, bigger axle flats, all tempered and case hardened $20-$60

milled sidecovers $40

Wiring upgrades done with Polarwire Arctic Ultraflex Blue in either 10 or 8 AWG. Want to know why I use this wire, just ask $35-$45

Hall sensor replacement done with genuine Honeywell SS41s, high-temp glue and wiring $40

All the mods done for 35 bucks off the total, $150 even.

These motors should be capable of some ridiculous horsepower, 10-15 kw is easy for these guys.

[edit] also, 45 bucks for matching clamping torque arms, also tempered and case-hardened. Built to fit [edit]





Speaking of the ranch, check it out: http://www.hadbf.com/ <- my grandparents ranch where the shops located

[RallySTX]

Nice work Farfle. Can't say enough about good machine work for these hubbies. I have two 9C's I would like you to hotrod. Are you inmterested in the job? I even have two other machine jobs that I would be very willing to pay to have done. They require machining half inch steel plate. Below is one item I need.



Also, are you ready to make 9 inch long X5 rear axles yet?
Brian L.

[Farfle]

One 5404 is reserved, two left, and 3 5403s unclaimed.

[wojtek]

i know it is hard for you to tell if you prob not have 54xx series in your hands, but taking that they are thicker, do you think you can put a new axle at 135mm? will it affect disc brake mount?

many members are asking about it actually as some cannot stretch their rear swingarms or don't want to. This could be an 1freewheel option. Maybe disc brake not possible. Still OK for trikes and maybe bikes with rim brakes. Would the wheel be still central?

I am curious about your opinion. Or anyone else

One 5404 is reserved, two left, and 3 5403s unclaimed.

[Farfle]

i know it is hard for you to tell if you prob not have 54xx series in your hands, but taking that they are thicker, do you think you can put a new axle at 135mm? will it affect disc brake mount?

many members are asking about it actually as some cannot stretch their rear swingarms or don't want to. This could be an 1freewheel option. Maybe disc brake not possible. Still OK for trikes and maybe bikes with rim brakes. Would the wheel be still central?

I am curious about your opinion. Or anyone else

One 5404 is reserved, two left, and 3 5403s unclaimed.

The motors position left-to-right on the axle is not critical, while machining new axles the dimensions can be changed. in regards to the motor themselves being wider, if i make the axle 135mm, the only way it can change is towards the cassette side, so yes, either a slimmer cassette or a single speed freewheel would be the only thing that work in that situation.

shouldn't be a big deal either way, the motor can be moved left-to right on the axle, and the disk brake can either be shimmed out, or machined back (a small amount, already caliper clearance issues) so alignment shouldn't be very hard.

[RallySTX]

I will have cash for one strap on Friday.
Brian L.

[wojtek]

Farfle,
have you thought of installing a temperature control as a part of your modification service?
viewtopic.php?f=1&t=25502

[Farfle]

After reading that thread and dooing some research, I bought 20. so yes i am now offering remoter temp sensor probes .

[wojtek]

excellent!
could you install it on my 3540? at what price?

[Farfle]

Probably do 30 bucks for them, its a pretty straightforward install, and I didn't pay a whole lot for them. Ill do one on your motor wojtek.

[wojtek]

cool! how about the bearings?

[gensem]

Hey Farfle,

I just had an idea, its a silly, but might help.

Our main problem is motor heat, thats why you drill holes on the motors, some people tried to attached computer fan/blowers to the bike frame to help cooling the motors, but this approach wasnt working.
It just occured me that we could just bolt a fan like this



directly to the motor covers and it would spin with the hub pushing a massive amount of air inside the motor hub. im also thinking a standard 135mm space would fit this mod and a single speed freewheel.

Hi quality(haha), mspaint drawing.



As I said, it does sound silly but could actually work and its cheap to do. Am I completely lost?

[Farfle]

Hey Farfle,

I just had an idea, its a silly, but might help.

Our main problem is motor heat, thats why you drill holes on the motors, some people tried to attached computer fan/blowers to the bike frame to help cooling the motors, but this approach wasnt working.
It just occured me that we could just bolt a fan like this


directly to the motor covers and it would spin with the hub pushing a massive amount of air inside the motor hub. im also thinking a standard 135mm space would fit this mod and a single speed freewheel.

Hi quality(haha), mspaint drawing.


As I said, it does sound silly but could actually work and its cheap to do. Am I completely lost?

This would work great, but only if the motor was stationary. A hubmotor travels faster forward then the bottom blade, essentially making the fan pretty useless. Im experimenting with a few different cooling solutions.

[gensem]

I thought about the wind speed, thats why the design has an "intake wall", I knew the design would have a major flaw but it sounded to good and easy that I had to post it. =(

Im not really worried about running 10kw in a hub motor, its debris that scares me. Maybe an ITG hi flow filter would fit the bill (if it doesnt melt).
Talking about ITG always reminds me of forced induction... but thats gas stuff.


Would you mind to elaborate on your cooling ideas?