Replacement motor axles

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Tench
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Replacement motor axles

Post by Tench » Mar 30, 2014 7:22 am

There are one or two threads on the forum that mention I have made new axles for some people who have suffered failures (abused them until they broke! :-) )

https://endless-sphere.com/forums/viewto ... =3&t=56883
https://endless-sphere.com/forums/viewto ... =3&t=57628

Here are a few more that I have just made to order with non std modifications that will be going out in the next post.

These are for, from the top;

Latest Crystalyte X5 or H4 series,
3/4" dia journals and bearings, massive over size 3/4" unf threads, thread stopped short for maximum security in the 3/4"x 10mm drop out. Made in very tough!! EN24T, this one wouldn't break even if you mounted it only on one side!!

Crystalyte H3 series
3/4" dia journals and bearings, over size M14 threads, Axle extended 15mm each end, thread stopped short for maximum security in the 14x10mm drop out. Made in very tough!! EN24T

The std Crystalyte axle has 17mm journals and shielded but not sealed bearings with an 1/2" unf thread (12.7mm) and is made from a very soft material. With the flats measuring 10mm this provides very little for a drop out to work on to prevent axle rotation and damage, perfectly adequate for its intended use of sub 1000w but loads have suffered failures when using them at many multiples of that as ES members do!!

These much stronger than standard EN24T axles can be made as direct drop in replacements or include modifications to suit your individual needs. Replacement std size but double sealed bearings or the 40x12x3/4" double sealed bearings can be also be supplied as well as nuts/washers to suit your chosen thread.
Unless your modifications add a great deal to my manufacturing they cost £100 inc bearings/nuts and washers.

I have a V1 Cromotor here too so I can shortly add that axle to the list of ones I make replacements for.

The bottom one is for my own HT 3525 in Titanium.

Image

And one fitted into an HS3540.

Image
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mvly
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Re: Replacement motor axles

Post by mvly » Mar 30, 2014 10:22 am

Any plans for the TC motor? Might need one down the road if mine fails. : )

Tench
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Re: Replacement motor axles

Post by Tench » Mar 30, 2014 1:24 pm

All I need is a drawing or an old axle to copy so crank it up and see how much it takes to bust it!! :-)
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The uk's first Stealth Bomber

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cal3thousand
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Re: Replacement motor axles

Post by cal3thousand » Mar 31, 2014 5:30 pm

I'm excited to get my new axle :D

Any updates Simon?
Get a Cycle Analyst and a Multimeter, you're still a noob if you don't have at least one of each.

Planning on posting questions or buying anything on this site? Put up your country (at minimum) on your profile. This is a worldwide forum and we haven't reached clairvoyance.

Tench
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Re: Replacement motor axles

Post by Tench » Mar 31, 2014 5:46 pm

cal3thousand wrote:I'm excited to get my new axle :D

Any updates Simon?
Should be going in the post tomorrow, it is just finding the time to get to the PO!

Yours is one of those in the pic!
Project one https://endless-sphere.com/forums/viewto ... ilit=tench
Project Two https://endless-sphere.com/forums/viewto ... =6&t=37489
The uk's first Stealth Bomber

There is a box inside your head, inside amongst others are the words "Wont fit" stop looking for answers in the box, there are no answers only excuses.

davec
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Re: Replacement motor axles

Post by davec » Mar 31, 2014 6:07 pm

very cool
this would be real useful for the xlyte 5403-5404 or even cro to make it fit a standard 135mm drop out :)

bhaydonsuperpocket
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Re: Replacement motor axles

Post by bhaydonsuperpocket » Apr 14, 2014 12:49 pm

Nice work mate. Iam arfter a 9c axle. Mines strip threaded. But I've got It.Phone much to get one if I sent.u SMS old one. Tar

Tench
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Re: Replacement motor axles

Post by Tench » Apr 14, 2014 1:17 pm

davec wrote:very cool
this would be real useful for the xlyte 5403-5404 or even cro to make it fit a standard 135mm drop out :)
I have a V1 cro here which is next on the list, and that was an idea I had too! so I will be looking into the possibility.
bhaydonsuperpocket wrote:Nice work mate. Iam arfter a 9c axle. Mines strip threaded. But I've got It.Phone much to get one if I sent.u SMS old one. Tar
You have a pm.
Project one https://endless-sphere.com/forums/viewto ... ilit=tench
Project Two https://endless-sphere.com/forums/viewto ... =6&t=37489
The uk's first Stealth Bomber

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joe tomten
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Re: Replacement motor axles

Post by joe tomten » Apr 17, 2014 6:42 pm

Do you think it is possible to do a 9c as a single sided mount axle?

I have a few motors here that I'd like to use for a tadpole trike. But the front 2 motors really want to have a single attachment to the double a- arm suspension.

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madin88
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Re: Replacement motor axles

Post by madin88 » Apr 25, 2014 12:11 am

please add cromotor V2 to your list. of course, in titanium :)
- Votec V-FR frame / MXUS 3T / 17" Mitas MC11 / Adaptto Max-E / 20s12p 25R -> approved as L1e moped and fully road legal in EU :)
- Vector white / MXUS 4T / 24" Hookworms / Adaptto Max-E / 22s11p 25R
- KTM Hardtail Pedelec / eZee V2 6T / 27,5" / Kelly KBSX @ 1,5kW / Torque PAS / CA-V3 / 13s4p Sanyo GA in Shark case

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ridethelightning
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Re: Replacement motor axles

Post by ridethelightning » Apr 25, 2014 4:08 am

here are some pics from a happy customer :D :D :D

custom 4065 axle with larger id bearings and deeper phase channel etc etc , and broken original clyte axle to compare.

its the same axle as seen above in tench's pic.

thanks again tench!
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Willow
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Re: Replacement motor axles

Post by Willow » Apr 25, 2014 4:16 am

10 times better.

Tench
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Re: Replacement motor axles

Post by Tench » Apr 25, 2014 4:46 am

joe tomten wrote:Do you think it is possible to do a 9c as a single sided mount axle?

I have a few motors here that I'd like to use for a tadpole trike. But the front 2 motors really want to have a single attachment to the double a- arm suspension.
This is not something I have done before on any motor, i don't have a 9c to hand to see if it would allow a larger journal dia, if the axle dia can be increased a little then i don't see why an axle made from EN24T would not be strong enough, what bearings does the 9c have fitted?
Last edited by Tench on Apr 25, 2014 4:51 am, edited 1 time in total.
Project one https://endless-sphere.com/forums/viewto ... ilit=tench
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The uk's first Stealth Bomber

There is a box inside your head, inside amongst others are the words "Wont fit" stop looking for answers in the box, there are no answers only excuses.

Tench
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Re: Replacement motor axles

Post by Tench » Apr 25, 2014 4:49 am

ridethelightning wrote:here are some pics from a happy customer :D :D :D

custom 4065 axle with larger id bearings and deeper phase channel etc etc , and broken original clyte axle to compare.

its the same axle as seen above in tench's pic.

thanks again tench!

Your welcome! You wont break that one!
Project one https://endless-sphere.com/forums/viewto ... ilit=tench
Project Two https://endless-sphere.com/forums/viewto ... =6&t=37489
The uk's first Stealth Bomber

There is a box inside your head, inside amongst others are the words "Wont fit" stop looking for answers in the box, there are no answers only excuses.

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Re: Replacement motor axles

Post by Swede » Apr 25, 2014 6:29 am

Hello..
How much for one axel to the H4080 hub with shippment to Sweden?

Regards
Jonas

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madin88
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Re: Replacement motor axles

Post by madin88 » Apr 25, 2014 6:57 am

Tench wrote:I have a V1 Cromotor here too so I can shortly add that axle to the list of ones I make replacements for.
it would be nice if you could fabricate a cromotor V2/V3 axle. I think not many do have a V1.
with the same wire outlet like on your H40 axle and for 150mm dropout it would be best i think. what do the other cromotor owners say?

you do really well design and fabrication. great job.
- Votec V-FR frame / MXUS 3T / 17" Mitas MC11 / Adaptto Max-E / 20s12p 25R -> approved as L1e moped and fully road legal in EU :)
- Vector white / MXUS 4T / 24" Hookworms / Adaptto Max-E / 22s11p 25R
- KTM Hardtail Pedelec / eZee V2 6T / 27,5" / Kelly KBSX @ 1,5kW / Torque PAS / CA-V3 / 13s4p Sanyo GA in Shark case

Tench
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Re: Replacement motor axles

Post by Tench » Apr 25, 2014 7:04 am

Hi Jonas, a standard replacement axle would cost £90 shipped. I can also change the thread or add some length, stop the thread short of the shoulder where it sits in the drop outs, bigger wire channel etc, or even increase the journal dia to 3/4" for the same price.

If you would also like new bearings I can supply double sealed bearings for additional cost.

Cheers Simon.
Project one https://endless-sphere.com/forums/viewto ... ilit=tench
Project Two https://endless-sphere.com/forums/viewto ... =6&t=37489
The uk's first Stealth Bomber

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joe tomten
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Re: Replacement motor axles

Post by joe tomten » Apr 25, 2014 7:06 am

the 9C bearing is a 6202 bearing.

journal diam: 15mm
OD : 35mm
width: 10mm

Tench
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Re: Replacement motor axles

Post by Tench » Apr 25, 2014 7:20 am

joe tomten wrote:the 9C bearing is a 6202 bearing.<br abp="817"><br abp="818">journal diam: 15mm<br abp="819">OD : 35mm<br abp="820">width: 10mm
I will look around to see if I can find a bearing that could be used to allow a thicker axle to be fitted.

madin88 wrote:
Tench wrote:I have a V1 Cromotor here too so I can shortly add that axle to the list of ones I make replacements for.
it would be nice if you could fabricate a cromotor V2/V3 axle. I think not many do have a V1.
with the same wire outlet like on your H40 axle and for 150mm dropout it would be best i think. what do the other cromotor owners say?

you do really well design and fabrication. great job.
Thank you!
I have a new build going on at the moment which I think is head and shoulders above what I have done before, this time the frame has been drawn up so I can reproduce it if people want one. I am just waiting on a few small parts so I can finalise a couple of small frame details before construction starts. My Cro may go into one of these frames but the first bike is getting my lightened HT3525 in it.

I have not pulled the axle out of my V1 Cro yet, is there much difference between the different versions?
Project one https://endless-sphere.com/forums/viewto ... ilit=tench
Project Two https://endless-sphere.com/forums/viewto ... =6&t=37489
The uk's first Stealth Bomber

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ridethelightning
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Re: Replacement motor axles

Post by ridethelightning » Apr 25, 2014 8:33 am

very keen to see this new build of yours. let me know ifyou post pics

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Re: Replacement motor axles

Post by mvly » Apr 25, 2014 11:47 am

Wonder if it is cost prohibit to get on in titanium. : )

Tench
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Re: Replacement motor axles

Post by Tench » Apr 25, 2014 12:16 pm

ridethelightning wrote:very keen to see this new build of yours. let me know ifyou post pics

No pics till its finished! 8)
mvly wrote:Wonder if it is cost prohibit to get on in titanium. : )

I have used Ti for my own HT3525 axle, saves about 300g but costs £40 for the material and its even tougher than EN24T to machine!!
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Project Two https://endless-sphere.com/forums/viewto ... =6&t=37489
The uk's first Stealth Bomber

There is a box inside your head, inside amongst others are the words "Wont fit" stop looking for answers in the box, there are no answers only excuses.

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Re: Replacement motor axles

Post by Swede » Apr 25, 2014 1:38 pm

Hello Simon
i will get back to you when i am ready to order..

Regards
Jonas

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joe tomten
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Re: Replacement motor axles

Post by joe tomten » Apr 25, 2014 2:47 pm

For that 9C:

Looking here : http://www.microbluebearings.com/pages/ ... HARTS.html

it looks like a 6003 bearing will bring me up to 17mm journal size still fitting in the 35mm housing.

the 6003 seems common enough;

though is the extra 2mm enough to warrant the effort ?

I have not found any Timken bearing in that 17mm ID / 35mm OD size that would be suitable for the outboard bearing of the single axle connection (if that is really needed for lateral loading).

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Re: Replacement motor axles

Post by Tench » Apr 25, 2014 3:57 pm

17mm might be sufficient, do you have a drawing of the 9c axle as I don't have one to work from?
I would also need to know the detail of your chassis fixing for the axle.
Project one https://endless-sphere.com/forums/viewto ... ilit=tench
Project Two https://endless-sphere.com/forums/viewto ... =6&t=37489
The uk's first Stealth Bomber

There is a box inside your head, inside amongst others are the words "Wont fit" stop looking for answers in the box, there are no answers only excuses.

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