FS Frame + Cromotor + Lipo

[kfong]

Carbon fiber cloth. This is how carbon fiber bikes are done by DIY. Use several layers to create a very solid structure.

[gensem]

Thanks, ll try if the glue fails...
The glued area is big, like 1,5inch x 4inch hoping it doesnt fail on me.
have a look

[kfong]

Looks like you are adding a piece of half round aluminim tubing to the section. That should work too. Just as long as it conforms well to the area. I think you need to mix the epoxy.

[Doctorbass]

looking at the surface aream, you can hold tons of force without problem

But, iyt all depend on the precision you cleaned and grinded the surface to be bond.

If yo apply epoxy to painted surface, it will be as strong as thej paint bonding itself.

If you correctly grinded the paint to remove it all and have fresh aluminum or steel to bond, result should be perfect.

Doc

[gensem]

Tube was not perfectly round, but the result should be good. I made sure to clean the surface with a hand steel brush. deviation is 0,6mm and it was filled with DP420.

[kfong]

Looks like a lot of contours to deal with giving you pockets of epoxy. I think I would of gone with layers of carbon fiber. But you have to isolate the carbon from aluminum due to electrolysis. A separating layer of fiberglass can be used. So it would be a coin toss as to what would work better. You can use carbon tow (rope) as a wrap to go around the bottom bracket. That would be a better way to structurally secure it.

[Doctorbass]

It is preferable to use EC2216 epoxy for carbon fiber. but it is less strong with aluminum and steel... no real trade off for both carbon fiber and steel or aluminum.


The EC2216 is also a 3M scotchweld structural epoxy like the DP420 but is a little bit softer.

The 2216 is used by the aerospace since the 60'

Doc

[Doctorbass]

I can say... no need of filling with carbon fiber.. the DP420 is REALLY strong!

The DP420 is also a structural adhesive

Doc

[fabiograssi]

+1 on only 420. That adhesive is a beast!

I can say... no need of filling with carbon fiber.. the DP420 is REALLY strong!

The DP420 is also a structural adhesive

Doc

[gensem]

More dp420 to fix Doc torque arms.

[GCinDC]

replacement frame - sweet!

is this the old frame w/ cromotor from that thread?

if so, what happened to the frame? looks like it got crushed..

did you just send a pic of swing arm crack to seller to get the replacement? awesome...

[gensem]

Yes, its the same frame only the color differs.
I ended welding some pieces to the frame to find out the heat plus a very small pressure cracked the swingarm bushing.
Its looking bad because I sorta beat the frame when I saw the crack.
I was willing to pay for a new frame but the seller asked just a hundred bucks for shipping and that was after I told him the frame was modded and thats why it cracked.

replacement frame - sweet!

is this the old frame w/ cromotor from that thread?

if so, what happened to the frame? looks like it got crushed..

did you just send a pic of swing arm crack to seller to get the replacement? awesome...

[gensem]

Sneak peek



Should have something running(testing) tomorrow.
You know what a big fork and 24" makes me think..... alot of room for batteries under the down tube, might worth testing later,

[BATFINK]

Looking good gens em, what made you decide to weld that battery holder plate straight onto the headset instead of the clamps like what Oatnet did with his? I think I'm going to do a similar mount of my batteries but I will try to think of a way to do it so the battery box is removable for charging.

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[BATFINK]

How many volts and amps can you fit into that pelican case?

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[gensem]

Looking good gens em, what made you decide to weld that battery holder plate straight onto the headset instead of the clamps like what Oatnet did with his? I think I'm going to do a similar mount of my batteries but I will try to think of a way to do it so the battery box is removable for charging.

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Its not welded, it was glued with DP420. I think they weight would mess with the bike handling.
I did not think about doing a removable mount, but I might come with something diferent at a later date.

[gensem]

How many volts and amps can you fit into that pelican case?

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im fitting 24s 2p of zippy 8000mah (hobbyking lipo)
90v x 16a = ~1500wh
1100-1200wh usable 80%DOD

[BATFINK]

Thanks that's great. Keep up the god work

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[oatnet]

Its not welded, it was glued with DP420.

What a great idea gensem! Here I have been toying with the idea of welding a block like yours onto my second frame, weighing concerns about deforming the headtube and the need for heat treating, and I never once considered using the DP420 epoxy Doc has been recommending for his torque plates. Gensem, you just advanced the design of front-mount batteries again. Heck, instead of needing a double-crown fork for mounting, a single-crown fork will let you mount the box even closer.

Thanks!
-JD <--------- pondering the implications

[gensem]

Its not welded, it was glued with DP420.

What a great idea gensem! Here I have been toying with the idea of welding a block like yours onto my second frame, weighing concerns about deforming the headtube and the need for heat treating, and I never once considered using the DP420 epoxy Doc has been recommending for his torque plates. Gensem, you just advanced the design of front-mount batteries again. Heck, instead of needing a double-crown fork for mounting, a single-crown fork will let you mount the box even closer.

Thanks!
-JD <--------- pondering the implications

Hehe... Dont weld it, I dont think all the headaches are worth... try DP420, I think its strong enough, and ll find ouy next weekend.
Wont deny I have a steel cable hooked up just in case my lipos decide to fly.
To be truth I like the box far because it good against wheelies, but It odd to not see the front wheel. I need to finish the bicycle assembly so test it further. If I find it bad while riding I ll swap the fork for a single crown.

Btw the pelican is somehow removable now, and lipos ll probably be perma paralleled because I dont have room inside the box for all thoses wires.

Regards

[gensem]

Couple more cell phone pictures. Folks, please remind me to not do everything custom next time... Its alot more work that I could dream off.

[fabiograssi]

Hey, Gensem, that's a "honda CG" horn in your machine???? Oh, what a dream if I was in traffic at Rebouças avenue and a cromota beast pass by horning insanely!!!!!

Nice build, my friend!!!!

[gensem]

small update... did my first run today using a 12fet controller 100v and 50phase amps... even with a shitload of weight in the fork I keep seeing the sky easily aside that the throttle is too frocking sensible, like a wild animal. I was a short ride, but was breath taking...
Will try to use capacitive throttle later and fix some other stuff I just found out.

[oatnet]

small update... did my first run today using a 12fet controller 100v and 50phase amps... even with a shitload of weight in the fork I keep seeing the sky easily aside that the throttle is too frocking sensible, like a wild animal. I was a short ride, but was breath taking...
Will try to use capacitive throttle tmr and fix some other stuff I just found out.

Yep, that is why I wanted the 13kv winding instead of the 9kv. Once you reduce rim diameter enough to get the 9kv into a Moto tire that is safe at the speeds it can generate, the torque is enough to impact drivability for my style of riding. OTOH, there are a lot of people who like having the front wheel off the ground as much as possible, this winding is great for them.

Throttle response can often be attributed to the controller. Kelly controllers have a setting to reduce throttle response, that helps. As an alternative, you could try reducing power.

-JD

[BATFINK]

Hello gensem, can you tell me what voltage that electric horn is? is it just a standard 12 motorcycle horn? did you use some sort of converter to step the voltage down for it or are you running a separate battery for the horn? I have 48 Volt battery pack is there any electric horns that will work on that voltage?
Thanks