Custom Ebike Parts [Was custom X5 axles]

[Farfle]

Formerly the custom X5 Axle thread.

[Edit] Now doing clamping torque arms and other E-bike metal fabrication/ motor modification[Edit]

Hello all, These Axles are for the the crazy-high power x5 abusers, those who have high regen braking, or people who cant have a sturdy torque arm due to dropout construction etc.... They are made by modifying the standard X5 axle in a process that involves pressing the axle out, TIG welding an additional section of axle flat to both ends of the axle, machining the axle flats to more precise tolerances, machining the wire exit groove to a much larger size, smoothing and rounding the wire exit point, and then a final hardening with Kasonite powder.

Either you ship me just the axle, ship me the motor and I will press it out, or whatever you need... Prices will vary based on what you want done, but will probably start at $25. I can do other machine work as well, custom parts, bad-ass torque arms, anything in reason. Shoot me a PM.

Here are a few images of a completed one, This is the first model, the surface of the axle flat looks a bit rough because milling something after you case-harden it, has less than optimum results... .

[Farfle]

Not much interest in these?

[MadRhino]

Yes of course, but shipping so far back and forth one of my Clytes is a turnoff, price and time wise. I believe that you'd have alot more success with offering ready made custom axles or better, pre-mod Clyte motors ready to ship.

I will take info about shipping an X5 to your place, maybe it's not as bad as I think.

[Farfle]

ok, interest check: there anyone who would be interested in buying a custom machined axle? it looks like about $30-$50 cost per. Going to order a sample of steel and machine a few, should be available in a few weeks.

[MadRhino]

Good, I'll take the first one made, and a few more if I like it. Make it longer, some half inch extra screw each side, to be able to fit a longnut.

Thanks for providing such a usefull part for us performance builders, and at such a low price IMO.

Edit... PS: I, and I'm sure about a few other, would gladly pay 200$ extra for an X5 Clyte that would be improved with SKF bearings, custom axle, 8ga phase wires, silver soldering, temp probe...
Some cooling options and custom covers could be offered to make additional bucks.

There is a niche for this kind of mod. I personally, can't easily access the facilities, nor the available time, and would be very happy to pay the price if some motors were offered ready made for performance.

[Farfle]

If i had the capital, i would gladly do ready-made modifications for higher powered motors, I am going to be using the schools cad mill to make a set of vents in my own hub-motor, but I do not possess the tech to do that at my shop, as I only have a basic 3-axis mill and lathe, no shiny CNC stuff . But anywho, 5 feet of 1018 steel round stock is on its way, should be enough to make 4 or so axles with a bit to spare.

[Farfle]

Here is a few images of X5 side plates with cooling vents done on the CAD mill.

[Beavinator]

That looks pretty wicked!

[RallySTX]

Always after I buy something else! Farfle can you make a nine inch long X5 axle? I will be needing an X5 with one, and the cooling mods to finish my Spoiler. Better yet, can you do this for one of the new sensorless hubs from Maxx?
viewtopic.php?f=31&t=26500
I will have money available in a couple months. Right now I'm waiting on a shop to build tourqe arms, and an ES mamber to finish two battery boxes. I would be willing to pay your price to do the extra wide wire hole mod and install them too if you can. I am currently working with 9C hubs but I have low expectations for those. My bike will need the best! Thank you for your consideration.
Brian L.

[Farfle]

Always after I buy something else! Farfle can you make a nine inch long X5 axle? I will be needing an X5 with one, and the cooling mods to finish my Spoiler. Better yet, can you do this for one of the new sensorless hubs from Maxx? Brian L.

Yes I can . probably . Depends on how they are constructed. If the axles on the new HX series motors can be pressed out, I can make you an axle, not sure how they are constructed, IIRC if they are similar to a 9C motor with stamped sideplates, then the axles are welded in. checking with a few of the big heads on whether it can be pressed out.

[RallySTX]

Cool, I am interested one way or the other. I just need to finish up with these other projects first, then I'll be tapping on your skill set.I guess it is a bit early to expect the new HX series to be getting modded, so it's ok if we concentrate on an X5. I'm just looking for the best I can get for the bike. Thanks again, I'll be looking forward to doing business with ya.
Brian L.

[Farfle]

After some research, looks like the HX axles can be pressed out. so, HX motors are on the OK to mod list .

[RallySTX]

Awesome, I will let you know in the next few monthe when I am ready to buy one from Maxx. I will send it to you for the 9 inch axle and cooling mods. Then I will pay you to ship it to JRH for custom laceing into a wide rim. That's the plan. The reason things are on such a long time table is that I am disabled and live on a limited income. I will know more about the other jobs next weekend. I hope to hear from the other guys by then. I will be contacting them if I don't. Happy Memorial Day weekend to you.
Brian L.

[MadRhino]

Did you receive the steel to make the X5 axle yet? I have an X5 waiting...

A mod on an H Clyte sounds good, I'll have one as soon as you are ready to ship.

[Farfle]

No steel yet, should be here today or tomorrow. I may not be able to lathe axles for another week though, graduation is the top priority at the moment . Plus, going to be somewhat difficult to make splines in the outside of the axle where it is presed in, as I don't have a knurling tool. Yet . May have to build axles with keyways or other methods of friction-pressing like a slightly oversized axle that you have to freeze first and heat the stator with the heat gun. Not sure how well that will work... Maybe high-strength loctite? Anybody have any ideas? On another note, Here is what a completed hubbie setup will look like:

[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...