Recent content by ksithumper

Nice vid Rodgah! That method (broaching in the lathe) is exactly what we're planning, I've done that successfully before to cut a keyway on a steel motorcycle flywheel, and so an aluminium pulley should present no problem. It does need to be a tight fit though, or will just fret and wear...

We've made some more progress, mostly mundane stuff like spacers and circlip grooves and bearing caps to keep the shaft end floats correct. The pics below show how we cut a groove in the shaft to hold a half-moon key (we Brits call them Woodruff keys) to locate the input belt pulley. First...

Be careful, you can very easily distort the bore, effectively scrapping the fork leg. Keeping it cool when welding is key. Afterward, make sure the fork stroke remains absolutely free.

Love the vid, Toolman, that looks like way more power than we are going for - how many kW? We'd hoped to have the motor running submerged in the gearbox oil, both for noise isolation and cooling, but Astro aren't comfortable that the cable grommets will seal long term. We'll therefore amend...

Astroflight came back to me today; it seems their can is sealed for dust etc but they are not comfortable it would happily run submerged, the cable grommets aren't designed for that. I have thought of a possible solution, but for now will just tweak my design so the motor stays in the open air...

Thanks for the encouragement! Hoping to make a little more progress this weekend and put some more photos up.

Some more progress to share... My son used the Dremel grinder in the lathe again to cut the shafts down to the correct length, using a very thin disc. (it is too hard to cut or machine with conventional lathe tools). It looks very pretty with the lights off! Then he repeated the process at...

Ok, looks like we have the same issue to solve. I want to put my motor inside my 2-speed gearbox casing in an oil bath, mainly for noise reasons but also to keep it away from water and mud [and boy, do we have mud here in the UK...only for about 8 months of the year!!!] and to allow me to jet...

Did you work out how to seal cable penetrations of the can? (Or are they sufficiently sealed as standard, if there is no pressure in the coolant)? Thanks

Ecobogan, did you ever investigate externally water cooling the 3220, and in particular is the can already sufficiently sealed for that? Your bike is awesome by the way !

Hi, an accurate figure is not possible, as I did not have both halves of the original crankcase - and the new version is also far from finished. However, after borrowing the kitchen digital scales (sssh! :wink: ) my best estimates for the gearbox only (excluding primary drive) are: Original...

170 kwh?

Ron, thanks for your interest. I have lots of photos - just a few on here, and at low res. I'll take plenty more as the project continues! I should maybe better explain the gearbox casing concept - the whole oval will be wrapped in aluminium sheet to create a sealed oil containing unit. If...

Hi folks, sorry for the long delay since the last post- other stuff got in the way! Santa brought my lovely new adjustable boring head, and using that it was a straight forward job to bore the various bearing locations. Today we borrowed time on a milling machine and machined the edges of...

The power tools guys have the battery swapping down to a fine art. Would be cool to ride in, click in 2 or 3 or more 'bricks' depending on your need, and ride off. Bosch is well able to create a modular battery system for e bikes.