Stinky with 80-100 and Nuvinci. NEXT BIKE Teaser pic inside!

[E-racer]

The best the bike has done was 62 mph. Realistically it does 40 mph without completely destroying battery life. The 900 watt bulk charger works great and I am balancing using a RC charger. The $230 Turnigy battery pack has last 1,500 miles which is absolutely astonishing to me.



the bike


NEXT BIKE! This is an early design concept teaser pic. The frame will be possible thanks to Cartesian CNC profiling and bending http://www.cartesiantube.com/


The beginning


pickup tubes


pickup tube in swing arm tube with hardened shaft


assembly


Rear dropout section from the inside


motor mounts and Torlon chain tensioner


assembly


fully detailed left dropout assembly 1/4" 7075 plate


fully detailed right dropout assembly 1/4" 7075 plate


view of the right side with frame


2


motor in its place




2005 Kona Stinky


Stock 80-100 from Leader Hobbies with typical loose windings


Stock Windings Removed


Rewound 80-100 12 turns delta, 14gauge wire, 88kv


Rear View of Rewind this motors will be run with no skirt bearing.


Nuvinci Developer Kit and Surly Large Marge Rim


Wheel with Spokes! This is the first wheel I've ever laced, fun job! I recommend everyone do their own wheels.


Wheel Tire Package: Maxxis Hookworm 2.5 26"


Drive Train Layout from the bottom view.


Going to make a swing arm from 5"x2" 0.125" wall aluminum.

I am approaching my design freeze within the next 2 weeks. Unfortunately I had to wait until the nuvinci dev kit got here to make measurements for the custom dropouts/NV servo mount.

The batteries will be 12s Turnigy li-po mounted in the swing arm tubes. Balancing/monitoring will be done by 2 resistor modded cell medics. The controller is a Kelly kbl48201 100/200amp I will be running Burtie's linear optical sensors.

There will be no pedals. In Georgia mopeds/scooters don't require pedals or registration but are completely street legal any where except highways.

[Byte]

nice! I will follow this one

[GITech]

Wow, ha! How funny that I have been beginning to think along the same lines as your design.

I've also been staring at my bike for a year+ waiting to move forward with it.

Now that farfle is making custom 3" extended lowers for the rear suspension for my wally/kent Genesis I have been brainstorming with a similar drive idea.

(I know it's a wally bike, but it's the lowest cost frame that is close to a stinky (what I'd LOVE to have but is too costly for me), ...and by the time it is ready to ride the only stock parts left on it will pretty much be just the frame and rear suspension shock linkage. If I do a left hand drive from the rear lower, the stock peddle/chain system may stay... 'till it breaks)

I'll be watching!

Good luck,
Jay

[E-racer]

Added the sprocket today. Parts are trickling in from the expanses of the interwebz. I hope to be riding in 2-3 weeks!

[drewjet]

Looks like an intersting build, just be careful with the Nuvinci, as it is not happy at high power levels. I would definately keep it under 5KW. I toasted mine with 7500 watts.

[SamTexas]

Subscribed.

[E-racer]

Thanks! @drewjet, I am a little concerned about the power level. My Kelly controller is a 100amp cont 200amp burst. People seem to think the Kellys are over rated on current. I think that 100amp x 50 volt = 5kw before controller losses, motor losses, and drive train losses. I am pretty confident this will keep me in the safe zone. Time will tell. I was brainstorming the other night and though of trying to use an IR temp sensor to monitor Nuvinci temp. This might be useful if I am pushing the duty cycle limits.

[Kepler]

Looks like an excellent project. Also subscribed.

Great drawings too. What program are you using?

[E-racer]

Thanks! I use Inventor 2012 (free for students). Ill put some real renderings up when I design freeze, probably Monday. These currently have no attention to lighting.

[E-racer]

The rear end is all finally hashed out. Steel drop outs bolted to the aluminum extrusion with the NuVinci servo mount holes incorporated. I'm so close to being ready to build!

[Byte]

Is that how the bike is going to look when it's done? If so, niceeee color combination

[kfong]

Nice work, I would of used a thicker chain for the final output stage. The #25 stretches too much.

[GITech]

VERY nice E-racer!

Can't wait to see/read about the build!

Do you know what the current rating of your custom 12t 88kv motor will be?

Later,
Jay

[E-racer]

I use #25 on my Goped and yes it does stretch but its cheap and I just replace it once a year or so. The major advantages are its packaging size and off the shelf sprockets available for the Nuvinci flange.

The current rating is all based on what the controller can feed. My controller is 100amps X 48volt = 4800 watts. This figure is before losses.

[farmkid4]

Do you have any more pictures of the cad?

Looks great! cant wait to see more progress!

[E-racer]

[E-racer]

Did a fork rebuild today on my Marzocchi Drop Off triple. New Marzocchi seals, and new 7.5 weigh fork oil. Should be ready to ride!

[E-racer]

Exciting Day! First off, My rewound 80-100 runs with Burties optical board and the Kelly KBL controller! Secondly, all the aluminum is here!



Here is the assembly taken apart a bit.


The pickup point tubes will be made out of this 1.5" OD x 1.0" ID 0.25" 6061 tube.


The Inserts will be made out of this 1.25" OD solid 6061 bar.

[edudins]

Hey! Where did you source the sprocket that goes on the 80100? I'm having some difficulties with the drive train design on mine. I was planing to make a FWD ebike, with a 80100 going to a hub, and I need to keep in mind that one of those has to be a freewheeling sprocket, otherwise the rolling resistance would be huge, and I want to pedal also when the battery is flat

[E-racer]

Sprockets are readily available from http://www.mcmaster.com or http://www.electricscooterparts.com/ You'll have to take your freewheel advice from somone else. I don't mess with them (no human pedals) and the Nuvinci hub freewheels.

I NEED DROPOUT ADVICE!
I am seriously considering changing my dropout material from 1/4" thick 1018 steel to 1/4" 7075 aluminum. Everything else on this swing arm is aluminum. I am pretty confident the 7075 would hold up. The main issue I am seeing is that the supplied torque arms only have 1/8" engagement into the dropout. Any input? What kind of torque does the axle on this thing see?

[Kepler]

I would think that the Aluminium dropouts will be fine. Most of the torque is going to wheel not the dropouts. You only need super beefy dropouts with with high powered hub motors that transmit all their torque to the dropouts.

[biohazardman]

I thought that the Nu-Vinci axles were posed to be mounted on horizontal dropouts. Are you mounting them other than that?

[E-racer]

I thought that the Nu-Vinci axles were posed to be mounted on horizontal dropouts. Are you mounting them other than that?

"The preferred mounting includes horizontal dropouts to allow for chain/belt tension adjustment,
though vertical dropouts can be used with a chain/belt tensioner (not included)."
http://www.fallbrooktech.com/docs/DevKit_Manual.pdf


O! and an update on the bike! I'm almost done with the machining! spent 14hrs in the machine shop at my school today. We got a completely new building and a really great new lathe since I last worked in that shop. All is going well. I will post pics after I do my final cuts.

[biohazardman]

Thanks, missed that little bit so guess I will not waste so much time looking for horizontal dropouts from now on.

[E-racer]

pickup tubes


pickup tube in swing arm tube with hardened shaft


assembly


Rear dropout section from the inside


motor mounts and Torlon chain tensioner


assembly


fully detailed left dropout assembly 1/4" 7075 plate


fully detailed right dropout assembly 1/4" 7075 plate


view of the right side with frame


2


motor in its place