NEM0 - <$1k Electric Dual Sport

[vanilla ice]

Oh man that sucks about the treadmill motor. I was hoping that thing would work well.

[TylerDurden]

Yeah, bummer... I was hoping to see a treadmill motor actually work. I guess they always sucked, always will.

The bike is awesome. One of those 12KW outrunners, or a pair of astros might be the ticket.

[TylerDurden]

Thanks for documenting this bike to the point that you've taken it.

+1

For inspiration, or at least a pleasant distraction... check out widodo's thread on alternator conversion:
http://endless-sphere.com/forums/viewtopic.php?f=30&t=16328

[vanilla ice]

Yea I was thinking that also.. the alternator thing goes with the low budget theme of this project. Seems extremely involved though.

[captainslug]

Well, looks like I'll take one last stab at this. I've ordered the motor I ORIGINALLY INTENDED TO USE. A MY1020 rated for 60-volts.

http://tncscooters.com/product.php?sku=106185
The only problem I had with the first motor was that it wasn't able to handle the higher RPMs that resulted from over-volting. It never had any issues with the loads placed on it otherwise.

I also have a plan for mounting it so that I can get rid of the belt tensioner.

[captainslug]

If the single MY1020 rated @ 60 volts proves inadequate, then I have no affordable alternative to consider.
At that point this project will change hands to someone that can afford a more powerful drivetrain.

[captainslug]

Motor is installed. In order to get the pulley on the drive shaft of the motor I had to tap and bore opposite ends of its ID. The thread isn't a perfect match, but its good enough to keep it locked on tight.

The self-retracting extension cord reel fit nicely when wedged into the bottom of the frame. Which I'm very pleased about.

I made a replacement idler sprocket using a cheap freewheel, and an aluminum freewheel adapter from recumpence, which I lathed down a bit and then stuck a sleeve bearing inside of it.

And that's all I could get done today.

[mdd0127]

Don't get discouraged. It's an awesome project, but at 200+ lbs, you're going to need 5-6kw to be reliable and interesting. It's just a fact of physics. If you still can't afford a decent motor by the time I get things really rolling, I'd be happy to donate a motor to your build. I'd start saving for lipos for sure. Again, very impressive build.

[vanilla ice]

I still thinks its a neat little budget moped. The looks is what is throwing everybody off. If you think of it as a dirtbike that happens to have a moped plate, sure the performance isn't up to snuff. If you look at it as a moped that happens to have dirtbike looks, the performance of the original build already had it outperforming ice mopeds.. Any case I understand the desire for higher performance and I hope you find it!

[Jay64]

I hate to see the project end. I truely hope that you get it to work to your expectations. But if you decide to sell it, hit me up and let me know a price. I have a bunch of lithium batts, and a few high power motors. I am always looking for more chassis, and your build is an absolute beauty.

[captainslug]

This project seems to hate me. I now have one dead battery and the DC converter no longer seems to be working.

If anyone wants to buy this project it's yours for $1000 + shipping.

[toyguru]

Buy it Jay, I would love to see this thing rock with an Agni and lithium batts

[Jay64]

captainslug, I'm talking to my business partner about this project. I just recently bought a couple of non running bikes, so I am kinda in the hole, but I would really like to continue this project. So I am checking to see what we can work out with this.

[Jay64]

Btw, where are you located? (For shipping reasons)

[captainslug]

Btw, where are you located? (For shipping reasons)

Sterling, VA

Replying to your other questions via e-mail.

[captainslug]

I tore the electricals apart today and will be making one last attempt at getting this bike working. I've ordered a replacement DC converter which should be more robust than the other much cheaper ones I seem to be killing.

[Jay64]

Good luck at getting it working. If you still decide you want to sell, hit me up on email again.

[dangerzone]

I tore the electricals apart today and will be making one last attempt at getting this bike working. I've ordered a replacement DC converter which should be more robust than the other much cheaper ones I seem to be killing.

There is an electric motor that might be best for your frame, it is a 12kW outrunner with hall sensors and optional water cooling which does not cost much, the Colossus.

viewtopic.php?f=30&t=16728&start=345

This motor is only 5kg heavy so you could put it on top of the rear fork instead of inside the bike frame. That would also mean less chain and no need for chain tensioners.
Yet those batteries would be a bit underpowered but it is worth a try, the performance would definitely be comparable to a 125cc dirt bike.

[captainslug]

I haven't had much free time to devote to this project lately. The replacement DC Converter DID arrive though.
I'm getting married in 2 weeks and my Tuesday and Thursday nights are taken up by the TIG welding class I'm taking all summer.

[captainslug]

I've made some progress on installing the replacement DC Converter. And while doing so I've updated the wiring diagram.

[grandmasterE]

Is this project dead? Too bad if it is.

E

[HumboldtRc]

I'm getting married in 2 weeks

That says it all.....

Edit: Weird coincidence both being at 59 posts...

[teddillard]

I just want to say... this has been the most inspiring thread I've read on a build in years. Great job, and I'm sure you'll get back to it in good time.

Thanks!

[captainslug]

Is this project dead? Too bad if it is.

E

Basically Yes.
I have no free time or money to put towards this seeing as I am currently working towards saving up money to buy a home.
I would both love and hate to work on this because I just can't afford to run into any further issues that would require that I invest more money to finish it. It's also looking like I will probably be moving to an area where I would no longer be able to really use this bike to get around town or to/from work.

I'm also just very tempted to replace the electric drive train with a small diesel engine.

[Gordo]

Is this project dead? Too bad if it is.

E

Basically Yes.
I have no free time or money to put towards this seeing as I am currently working towards saving up money to buy a home.
I would both love and hate to work on this because I just can't afford to run into any further issues that would require that I invest more money to finish it. It's also looking like I will probably be moving to an area where I would no longer be able to really use this bike to get around town or to/from work.

I'm also just very tempted to replace the electric drive train with a small diesel engine.

Beautiful build and I'm sure the education you gained is worth every penny you spent. There is nothing cheap about building an e-bike. When you try a motorcycle type build, you need $1200-$1500 for batteries and then another $2000 for the rest.
When you are young you have to set your priorities to meet your families needs. Work hard and smart and hope you get to a happy place soon where you can go back to building toys.
Thanks for taking the time to document your build. It was a most enjoyable read.