Custom Ebike Parts [Was custom X5 axles]

[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?

[Andje]

debris has never hurt anyone who drilled cooling holes. if you're really scared epoxy some window screen to the inside of the hub. there is no easy solution to cooling these hubs with forced air or fans; many members spent months investigating forced cooling, i think arlo1 and lightcycle did best with server fans in an x5 and with turbo forced air from outside the hub respectively. but it is so hard that most people skip it and just drill cooling holes; even people willing to rewind motors and build custom frames don't set up anything more then ventilation.

[darkshirikens]

How about something like a protruded cup about half or 3/4 the diameter of the drilled hole on the hub itself to catch the air and force it through the other side but the holes on the other side would be reversed and screen on the inside to keep most debris out the concept i'm thinking of would or should create like a wind tunnel affect almost just like when your going fast in a car and you cup your hand and stick it out the window and catch the wind its thought lol

[wojtek]

i had exactly the same idea in mind, but my english wasnt good enough to describe it

[gensem]

Wojtek my english is a crap too, Im Brazilian and never had english classes... just dont be shy and write. Even if its not right people can usually understand.
If you are out of words, Paint is there to help ya.

[Andje]

if you mean scoops to scoop the air into the motor they dont work. search the forum; they have been tried.

[darkshirikens]

Yes basically like a scoop their is too many variations to do it to say that they simply don't work then simply what do drilling holes in the cover work i admit it does give more breathing room inside the motor and it been in many shapes sizes and forms so what would be the difference in trying this approach till it works ? It will take time but it can work cause even the shape of a scoop can catch air its been proven in other applications so why not this one ?

[RallySTX]

Well, you first have to define the terms, work, versus don't work. If don't work means it helps reduce temps but not enough to justify the expensive work involved, or the scoops create so much drag that the bike is a dog, or they counteract their design due to drag losses, you see what I mean. Plus don't forget the earlier mention of the fact that this rotating fan is moveing, which reduces the bottom half of the cycle due to reverse air movement. I'm considering adding scoops at the back of my spoiler to direct more air toward the hub at speed. The hassle of not altering the frame in any way, and the weight of the already heavy bike are conspiring against that idea. But I believe it would help out. Too early to tell how bad the cooling issue will be yet.
Brian L.

[Farfle]

Sorry to say this, but real life has gotten crazy, and I won't be able to do any motor modifications until I get things ironed out. Probably will not be until fall term is done.

[Kirk]

By a any chance was your Mother frightened by a KMX while she was pregnant with you? I'm electrifying a couple of Catrikes an 05 Road (wife's) and a 2011 Expedition. Next on the list is a set of torque arms for them. I'm shopping around for a set of X54xx motors for them now. I'll get in touch about axles once they are in my grubby little hands and I know what I want.

[Doctorbass]

Can you make us a 5404 and 5403?.... i'm kidding...

[Microbatman]

Can you make us a 5404 and 5403?.... i'm kidding...

I think that the answer is Yes. We (forum members) can do it.

That is together the brains/knowledge/skills of those on this forum it could be done. I say we go for it. Especially after the news of the X54XX being cancelled changed or whatever you want to call the misshap.

My contribution would be to work and be the leasion with the lamination manfacturer. I would do the work of representing the goup and getting pricing for manfacturing what we need. So far the best choice I know of for this is http://www.protolam.com/ But I would also check out others and shop around for the best price/quality bang for the buck.


Other members here would neeed to figure out the
Case
Axel
Magnets (thicker? more poles? less poles? better material? cost of upgrading? and difference in performance)
Winding and pole layout scheme. (more poles/taller/wider/shorter?)

There is really not much more to do to get a product out that we could call our own.
We are probably alot closer and able to do this than we would give ourselfs credit for.

[Brother Paul]

To Farfle

Modifying HS3540 axle (bigger wire groove, bigger axle flats, new axle tempered and hardened)

I have old axle pressed out already, and can send it to you.

PM sent

BrotherPaul

[oatnet]

To Farfle

Modifying HS3540 axle (bigger wire groove, bigger axle flats, new axle tempered and hardened)

I have old axle pressed out already, and can send it to you.

PM sent

BrotherPaul

Suspect you missed his post 4 messages before yours:

Sorry to say this, but real life has gotten crazy, and I won't be able to do any motor modifications until I get things ironed out. Probably will not be until fall term is done.

[Farfle]

To Farfle

Modifying HS3540 axle (bigger wire groove, bigger axle flats, new axle tempered and hardened)

I have old axle pressed out already, and can send it to you.

PM sent

BrotherPaul

Suspect you missed his post 4 messages before yours:

Sorry to say this, but real life has gotten crazy, and I won't be able to do any motor modifications until I get things ironed out. Probably will not be until fall term is done.

Midterms are done, but still not ready to go to full-production, things should wind down at my job come winter, and ill be able to take more than just small odd-jobs.