Norco Empire 8150 build (page 20 pic heavy)

[Hyena]

Hyena, which freewheel/s are you referring to? GB output freewheel, freewheel crank/chainring or freehub?

I was referring to the rear wheel hub - I assume he's using a standard-ish one with the mention of 9 gears ?

[AussieJester]

Had a visit today from Paul this morning
and was lucky enough to get a looksee at the new frame
design, with Pauls permission i have posted it below
for others to checkout...



I LOVE the design myself, the frame will use FOX
rear shocks, IIRC Paul it was ~7-8in of travel more
than most will ever need... REALLY looking forward to the
first frame mate, with your L337 welding
and fabrication skills, this will be a piece of art and highly
sort after frame.


KiM

[Hyena]

Nice!
What is the battery capacity of the down tube ? Iooks like it'd hold 8 6S 5ah packs ? So 12S4P or 24S2P ?

[AussieJester]

Nice!
What is the battery capacity of the down tube ? Iooks like it'd hold 8 6S 5ah packs ? So 12S4P or 24S2P ?

Paul hasn't got his own internet access at the moment so will likely be a lil late
on replies so i'll jump in and answer this for you Jay as its a question
i also asked Paul myself this morning...The battery capacity within the frame is 15ah worth
of 6s batteries...

KiM

[Hyena]

The battery capacity within the frame is 15ah worth
of 6s batteries...

You mean 12S ?
She looks like it'd fit a little more that 3 single 6S packs mate

[es2150]

Rock on, can you say mountain cycle, having flashbacks from 1996. Single pivots are good, just have to use disc brakes. pretty much mandantory for ebike anyway though, keep up the good work.

[Timma2500]

...

[Timma2500]

...

[sico]

Hi Paul, great build That new gearbox looks like its should be a fair bit stronger than the old one.

Getting the gearbox mounted will be relatively easy, just time consuming with my high-tech drill press style of cutting lol

Have you considered using a jigsaw? I have successfully cut 12mm ali plate with mine. I use a coarse blade and spray constantly with kero. It still takes a while, but might speed up things a bit over the drill-press method.

Simon.

[Timma2500]

...

[sico]

Hi Paul,

KiM gave me the headsup on the group ride on Hyena's thread, so I'm hoping to take the day off and join you guys. My bike is pretty amatuer compared to you guys though

I'm in Cloverdale, did I read that you're down in Rockingham?

Kids are pretty good disease carriers, before I had mine I hadn't had a cold in years, now I get a couple a year

Cheers,

Simon.

[Timma2500]

...

[AussieJester]

Hey i just saw your build thread Simon, the Black Vigilante looks awsome! That'd be great if you could come along, the more the merrier Would be a good chance to see the Black Beast in the flesh too.
Yeah i'm down in Boganham ah i mean Rockingham... Cloverdales up near Kewdale isn't it? Can you tell i'm a banana bender fresh off the boat? lol
Kids are terrific disease carriers / spreaders, too good (the little turds!!!) in fact, i'm always catching a bug off them..


Paul

You poor sick bastard Paul

sico...Garret road bridge April 1st...

KiM

[sico]

Hey i just saw your build thread Simon, the Black Vigilante looks awsome! That'd be great if you could come along, the more the merrier Would be a good chance to see the Black Beast in the flesh too.
Yeah i'm down in Boganham ah i mean Rockingham... Cloverdales up near Kewdale isn't it? Can you tell i'm a banana bender fresh off the boat? lol
Kids are terrific disease carriers / spreaders, too good (the little turds!!!) in fact, i'm always catching a bug off them..


Paul

Cheers for that Paul, the bike is a work in progress but its coming up ok. Boganham, hehe , there are few bogans down there to be sure ... also a few up here in Bogandale. Yeah it's right next to Kewdale and, as the real estate ad said, close to international transport (the southern end of the airstrip is 1km east of me , but the serenity, ah the serenity ).

KiM, I'm onto it mate and I fully plan to make it down there if at all possible , as you said, its just around the corner

[waynebergman]

I am wondering if I am missing something here. It looks like a lot of Timma's posts have had there original contents removed. I flipped through all 20 pages here but did not see the photos that members were referring to from Timma's build? Would it be possible to edit the first post to direct folks to what has happened or where build pictures are.............thanks Wayne

[AussieJester]

Its because the pics have been removed when the forum
Was in threat of being commercialised, many memebers removed photos
Some may also be missing as a result of a botched forum upgrade prior
To the "unfriendly" take over. Reposting such a large quantity
Of pics over 20 pages is a bit of an ask im afraid. Many older
threads are like this unfortunately...

KiM

[waynebergman]

Thanks for this Kim. Its good to know. Just a respectful suggestion for threads that are in this condition to those that are able to edit on the behalf of others.......maybe an edit to the first post in the thread explaining what has happened. Something could be typed up and just pasted into these threads with holes in them on the first post on its first page explaining to new folks folks what is going on. Now that I know about this, I will save myself the searching next time but with this suggestion I am just thinking of those to follow.

Wayne

[farmkid4]

Hey Timma i would love to see the pictures from this build if you have a chance to update it. Been looking at some of you other builds great work!

[Timma2500]

Heys guys. I lost these pics ages ago when my hard drive crapped itself but only just remembered i'd posted them up on facebook at the time of the build.

Here they are:

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Paul

[farmkid4]

WOW

Thank you for posting these great work

[Hyena]

Wow those gears were really minced! What was the story with that again ? And what did you replace them with ?
I like the pic next to the turbo housing, that'd make a good inconspicuous gearbox side cover hanging off the side of the bike

[waynebergman]

Thanks Timma for taking the time to update the photos. Awesome. I am guessing you have fabricated the motor mount and battery holder out of 6061 aluminum. I am curious if a person finds a frame that is a candidate for such a project are you having to worry about the series of aluminum that the frame is made of or do you just go for it with the 6061 stock for the customizing and weld it to whatever the frame happens to be made of. My guess is that 6061 would work with most Aluminum frames but I am not sure. I am just learning to weld aluminum so parts of this are still unclear to me. Very nice bike by the way. Do you know what kind of range could you get out of your set up here say on a flat road going 30mph and no pedal assist, I am assuming with the ability to gear your drive you can get some good efficiency out of this bike?

[Timma2500]

Very nice bike by the way. Do you know what kind of range could you get out of your set up here say on a flat road going 30mph and no pedal assist, I am assuming with the ability to gear your drive you can get some good efficiency out of this bike?

Cheers. I wouldn't have the faintest idea on range etc on this build, the gearbox never lasted longer than 5km before stripping teeth off as per the pics above...

Actually thats a good point for anyone considering using a BaneBots gearbox - don't! They are cheap yes but they just can't handle any decent amount of torque or shockloading. You'd be better off getting a PLE80 sized Neugart planetary gearbox like the brand new 5:1 model i've just bought to rebuild this bike with (this time with an 80-100 outrunner instead of the Astro 8150). The PLE80's have a proven track record of standing up to decent sized outrunners and off road riding too (Burties Stinky comes to mind).

I am guessing you have fabricated the motor mount and battery holder out of 6061 aluminum. I am curious if a person finds a frame that is a candidate for such a project are you having to worry about the series of aluminum that the frame is made of or do you just go for it with the 6061 stock for the customizing and weld it to whatever the frame happens to be made of. My guess is that 6061 would work with most Aluminum frames but I am not sure.

The Norco frame itself is 6061. The sides i used were 12mm 5083 marine grade plate machined down to 5 and 10mm and the top plate was 3mm 6061 sheet. I'm pretty easy going and adventurous when it comes to welding different grades of ally together, but i figure if you over engineer what ever it is your joining, you can usually get away with it. At work we normally only use 6061 sheet, plate, tube and rhs/shs. With the exception being some 5083 from time to time. 6061 will normally play nicely with most grades.

Wow those gears were really minced! What was the story with that again ? And what did you replace them with ?

Yup, that happened on several occasions, normally after about 3 - 5km of riding - i never got any further without busting the planets!
I ended up buying several sets of spare planets and chewed through the whole lot before giving up on the Banebots gearbox, it was just too cheap, nasty and made of cheese!

I like the pic next to the turbo housing, that'd make a good inconspicuous gearbox side cover hanging off the side of the bike

Lol. If only the bike sounded like a turbo on song i'd be a happy camper... its from a mate's old Nissan CA18DET we squeezed into a Datson 1200 ute
A young guy bought the ute, rebuilt the engine with a biiiig TO4 based turbo, forgies, prog computer etc and a ford 9" diff. Lag city but it runs mid 10's on the strip..




Paul

[Samd]

Subscribed.

[Timma2500]

Subscribed.

This build is long finished Sam, however its soon to be rebuilt on this thread: viewtopic.php?f=28&t=35302
with a better quality gearbox, different motor, electrics and a touch more power.

Just slowly collecting some parts now


Paul