Belt driven off road bike (Giant Reign)

[1000w]

Hey Simon,
I use, https://sdp-si.com/eStore/
Click on the metric button at the top left then have a look for what you're after.
I have made 3 or 4 trouble free orders with them. Their shipping is very reasonable and there is no minimum order when using a credit card.
My latest order of 4 pulleys and 2 belts was $101 parts and only $15 shipping and handling.
Cheers,
Matt.P.

[sico]

Thanks mate, I just ordered a couple of pieces. They are much cheaper than small parts, I reckon they'll be quicker too (why does it take so long to get stuff from over east?)

[gtadmin]

Thanks mate, I just ordered a couple of pieces. They are much cheaper than small parts, I reckon they'll be quicker too (why does it take so long to get stuff from over east?)

Because Oz ends at the Blue Mountains, west of that is treated as another country

Great project, I love it

[dingoEsride]

Because Oz ends at the Blue Mountains, west of that is treated as another country

That may be true, it is a big land but here in the west there are those that make me proud to be a west aussie like Matt and his fine builds, looking at this one

[1000w]

Thanks Dingo,
Just a quick photo showing the rear frame triangle after the acid tank, ready for welding.

[AussieJester]

Thanks Dingo,
Just a quick photo showing the rear frame triangle after the acid tank, ready for welding.

Looks good Matt!! I didn't even think to tell you when i was speaking to you then, mate SnaPPeR
he just bought a sand blaster from Auto One for 36 bucks i think, comes with a 1liter bucket
of sand too! DiDn't i see a snad blast enclosure at your place? or was that someone else?

Anywayz, looking good mate, keep practicing the TiG and then get this sucker going! i wanna drag teehehe

KiM

[1000w]

I have finally found some time to weld the extended dropouts on to the rear end. I added some 10mm x 10mm bar at the top to help brace it all together.

[etard]

Simply beautiful Matt! You're welds are fantastic and that dropout is SOLID!

I too love the single stage reduction drive except one of these days I want to see how some of this #25 cam chain holds up in a similar application.

You are truly a pioneer in this aspect.

[magudaman]

Just curious if your planing on doing any sort of heat treating on the frame now that you welded it? Doesn't it create uneven strength on the metal creating brittle and soft areas from the heat?

Not sure how many watts your running but I found I was good to about 3300w on my 5mm gt2 setup with a 27T driver. Much smaller than that and I ran into problems with it hopping. Your idlers will help.

[sico]

Excellent Matt, looks like there should be plenty of strength there.

I guess it won't be ready for the group ride though, maybe the next one?

Simon.

[farmkid4]

lookin good! very nice job on the dropout

Will be watching

[1000w]

Thank you for the kind words etard.

Just curious if your planing on doing any sort of heat treating on the frame now that you welded it? Doesn't it create uneven strength on the metal creating brittle and soft areas from the heat?

Not sure how many watts your running but I found I was good to about 3300w on my 5mm gt2 setup with a 27T driver. Much smaller than that and I ran into problems with it hopping. Your idlers will help.

I'm hoping that I have over engineered this set up enough because I'm not planning on any heat treatment.
Whats involved in heat treating aluminium after welding it?
I've run 3700w with a 20T 5mm HTD driver faultlessly for 3000km and the charts say up to around 7000w is ok. This will be good test as I'm aiming for 6000w to 7000w on this build.
This photo shows why I needed an idler on the drive side of the belt to clear the frame.

I guess it won't be ready for the group ride though, maybe the next one?

I was hoping to have it ready for this ride, but I don't think so. Cheers, Simon.

Cheers, farmkid4

Ok, I have the rear end pretty much done now. The motor mount is in and the belt drive runs true and smooth.
I had to weld some small tabs on to the drop outs so I could use these nice tensioners that were kindly donated by Aussiejester.



Some minor interference with the brake caliper.



I made a plate to help brace the idlers.



Some general photos.

[E-racer]

Looks good! You can normalize the part in your oven at home if you wanted to. I'm no expert here but around 500degrees will realign the grain structure. I've heard of people using the oven clean setting to get their parts up to the required 750+ degree F it takes to get back to T6.

[GITech]

Wow, just saw this. Very nice job! What a work of art! I'm jealous! I need a welder!

Nice with the rims and tires! I bit the bullet and jumped right into something similar with my rim and tire choice to go with my design.

And Lily bit it too! "Is this my new teething ring daddy?" :mrgreen:


I can attest too the oven to re-harden 6061 aluminum when I did the front bumper for my custom 1/5 short coarse E-Maxx (my "SC-Maxx"). After annealing at 1000f+ so I could do the bending, it was very soft and very easy to bend, I think softer than 3031. To re-harden it I think I shot for about 375f for 7 hours in the oven. Doing this brought it back to I'd guess about 80% of it's original hardness.



I'll be watching your progress!

Later,
Jay

[sico]

Gee, I hope you have a massive oven then Mine certainly wouldn't fit it in.

I guess AJ won't let you get away without a few more lightening holes in the motor mounting plate. That cyclone motor isn't small at all is it? Looking sweet anyway dude.

Simon.

[E-racer]

Gee, I hope you have a massive oven then Mine certainly wouldn't fit it in.

You would be surprised at what fits in a standard oven with all the racks removed.

[1000w]

Just a quick update showing how I upgraded the motor phase wires and controller power and phase wires to 8g copper.

[GITech]

Nice to see the extra effort for efficiency Matt!

I wonder what can be done for ventalation of that motor?

You could certainly get a higher continuous duty rating if you could get some air exchange over those coils.

Jay

[etard]

Nice and tidy! Looks better than I thought it would, I wonder if putting a longer shock on would not disturb the handling too much and allow for better peg clearance by jacking up the rear a bit. I pray for your swingarm survival, those little loops for the bottom pivot scare me the most. Is it possible to reinforce them with just a plate cutout and welded around the profile?

[AussieJester]

Great job Matt coming along beauuudifully mate! LOL@ Sico re: lightening holes, i actally had that plate at my
place i took it too mates work to get the bending done, i should of drilled some lightening holes while i had the chance ROFL...

Look forward to seeing this one in person Matt, you should be able to make it ride-able for group
ride no? Looks like its well on its way to being ride-able... I seriously doubt the strength of the extensions will be an issue
its that over engineered...


KiM

[1000w]

I wonder what can be done for ventalation of that motor?

I was thinking the same thing, however I think I will leave it as is and see how it all goes.

I pray for your swingarm survival, those little loops for the bottom pivot scare me the most.

How come the loops worry you? They are unmodified.

I seriously doubt the strength of the extensions will be an issue
its that over engineered...

Cheers Kim, I hope you are right.
If putting this rear end in the oven on high for 7 hours will help strengthen it up, I will do it.
I need to find more info on normalising Aluxx SL aluminium. I found this in a search "AluxX SL starts with a 6061 alloy but mixes in a trace amount of copper to form a stiffer alloy"

[carl2.0]

Wow great mechanical design n craftsmanship. I NEED to see the finished product !

[1000w]

Ok this has been on the back burner for quite a while.
I just got the rear triangle back from the powder coaters, done in satin black.
I have done a quick assembly to see how it will look. The next stage is to mount the battery and controller and make a cover for them out of lexan.

[hillzofvalp]

That is pretty. How much does it weigh at this point?

[1000w]

That is pretty. How much does it weigh at this point?

Cheers hillzo, it's19kg as is.