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  1. L

    2018 Torque Arm Tests, Splined Interface Design and Tabbed Washers

    The Magnesium fork's dropouts look quite thick... but magnesium is a bit weaker than most aluminum alloys. My guess is this one will actually crack, not just spread open, and it'll happen at ~50 N-m. Stamped steel. Hmm... probably a generic "Hi-Ten" steel. I'll give it 70 N-m to full failure...
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    2018 Torque Arm Tests, Splined Interface Design and Tabbed Washers

    Thank you for taking the time to document this and make it publicly available, Justin! I've been somewhat involved in this project, but am continuously amazed by the time and care that you bring to the projects you take on. Seems that the torque arm failures are from the arm's teeth...
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    How to remove spindle on BBS01?

    Hi everyone, I'm trying to get to the bottom of an issue I'm having with a Bafang BBS01, and I can't seem to get the bottom bracket spindle out. All of the instruction videos assume that there's a 4-tab nut on the outside of the unit. That's not the case with mine: What you're seeing is a...
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    Bafang BBSxx - fault finding and fixes

    It's impossible to really tell from your image, but your larger gear doesn't look worn like mine. Anyone else ever had a gear that looked like this, and experienced a weird feeling from the drive?
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    Bafang BBSxx - fault finding and fixes

    Hey all- I've been searching and reading through this thread in the hope of finding someone with the same BBS problem that I'm experiencing, but haven't found it. I apologize if this is a redundant post! My BBS system gives a shuddering/vibrating feeling through the pedals when the motor is...
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    Max current for 9-pin motor connectors

    Hey Dogman Dan - That's awesome feedback. In your test, are you saying you're running 14S and 22A max current? 1000W seems like a reasonable max. Thanks!
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    Max current for 9-pin motor connectors

    What is the maximum current (and voltage) that the standard moulded 9-pin motor connector can tolerate? I'm talking about this connector: I searched around on the forum, and got unsubstantiated answers between 12 amps and 30 amps. I didn't find any reports of a failure of this connector. I...
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    Roller brake front motor - whines under load

    I bought a small geared front hub motor - I think it's a Bafang - from a chinese alibaba vendor: It's not a motor I've ever worked with before. I'm pairing it to this controller and an LCD from BMS battery...
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    How to eliminate pulsing/cogging on Bafang BBS

    I've played around with a few different BBS0X's, and in general I've found that they're pretty smooth, quiet, quality units. However, the pulsing/cogging in the lower PAS modes at low motor RPMs is driving me crazy! I find this problem is much worse on the BBS02 - I purchased mine (a 36V 500W)...
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    Cute Q100H - not reassembling properly...

    Thank you, Dani85, for the help! Placing the gears as you mentioned did make reassembly smoother. Now the motor doesn't freewheel in reverse, and there's a lot of drag - certainly more than there should be - in both directions. On the axle between the gears (shown in Dani85's pic above) there...
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    Cute Q100H - not reassembling properly...

    I haven't tried powering it back up, as I'd have to literally pound the side cover onto these gears. 2 of the 3 gears' teeth line up with the ring gear of the side cover, but not the third - they directly interfere. I think the side cover should just side right on... If I don't hear from anyone...
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    Cute Q100H - not reassembling properly...

    I'm using a Q100H mid-drive for a customized utility bike. I had to cut down the axles, and in the process stripped a screw that then required complete disassembly of the motor to properly fix. The motor seems locked up as I'm putting it back together. Notably, the planetary gears seem to be...
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    Has anyone bought the Panasonic 18650PF from BMS Battery

    I'm really curious about these cells. They have them stuffed into the nicer lockable frame mounted packs, and I'm considering ordering a couple to see how they handle. If anyone else has had experience with them I'd love an update!
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    DIY Ebrake sensor - which reed switch?

    I've been playing around with ebrake sensors, and I've settled on my favorite: http://em3ev.com/store/index.php?route=product/product&product_id=196 Super easy to use, NC, ready to go. Just 2 wires, too! You can also get them here...
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    Best RC motor for lightweight utility bike build

    Hey all, Thanks for the responses. Since we're in a time crunch on this project, and I still don't have confidence that I'll be able to do a good RC drive, I've decided to abandon an RC mid-drive in favor of a hub motor. But... will that hub motor actually be mounted as a hub? We'll see...
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    Best RC motor for lightweight utility bike build

    It may be helpful to give a little more information - it would be great to run this motor at 36V to pair with standard ebike batteries (we're eyeing the AllCell Summit). So that's 36V @ 2000 rpm... either of those numbers can change if there aren't any smallish (<2.5 lbs) BLDC outrunner motors...
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    Best RC motor for lightweight utility bike build

    Ok, reorienting back to my original question... :) I think that we can figure out the gear reduction ourselves - we have full access to a pretty incredible student machine shop - but the Astro 32xx does seem to be a favorite around here. I understand that it's customizable, sealed, and made in...
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    Best RC motor for lightweight utility bike build

    Hey all, I’m leading a team of mechanical engineering students building an ebike for a senior capstone project. I live in the pacific northwest (USA), and a recent survey found the top 5 barriers to bicycling in this area are: 1) The weather 2) Places I need to go are too far 3) The hilly...
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    Two Questions - BB Drive Systems

    My local bike shop offers Heli-Coil thread replacements for crankarms. It's pretty cheap (they charge $25) and they swear by them. I've used them on a stokemonkey setup before. So all you'd need are 2 matching left crank arms, and then you'd replace 1 of the pedal threads with a R-hand threaded...
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    DIY Ebrake sensor - which reed switch?

    Justin, you rock! In one line you got me on the right track. For those who like me didn't know this, an SPDT reed switch stands for "Single Pull Double Throw", and it has 3 leads - common, normally closed (NC, and normally open (NO). It turns out there are a lot more of these sensors. However...
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    DIY Ebrake sensor - which reed switch?

    Hi, I'm trying to figure out the best way to get ebrake functionality without having to use an actual ebrake lever. I'm tired of these cheap levers, and of course you can't use them for hydro! I've searched the forums for the reed switches folks from here have used, but pretty much all of them...
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    Proper controller

    Hi! I'm attempting to help out a friend who has a big electric cargo trike that recently stopped working. The original controller didn't respond at all (no voltage between throttle red and black, for example), so I decided to use one of em3ev's as a replacement (the 6 FET IRFB3077 INFINEON) and...
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    Connecting 10S Li-ion and 12S LiFePO4 in parallel

    I ended up getting the diodes that I had linked to earlier. Supposedly, they're rated to 20 amps each, and my setup was unlikely to draw more than 10A from the li-ion battery. Still, I was concerned that the diode simply looked so small, so I used two. I decided to attach them using JST-sm type...
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    Connecting 10S Li-ion and 12S LiFePO4 in parallel

    I ended up getting these: http://www.amazon.com/20L15T-Single-Schottky-Rectifier-TO-220AC/dp/B008LTKBBA/ref=sr_1_3?ie=UTF8&qid=1418972529&sr=8-3&keywords=schottky+diode&pebp=1418972533953 Cheap and quick shipping on amazon. I'm wandering in the dark here - I don't know a TVS diode from a...
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    Connecting 10S Li-ion and 12S LiFePO4 in parallel

    Thanks dnmum! Your explanation makes total sense. However, if I use a 15V diode and for some reason the li-ion pack isn't connected (or shuts off due to low voltage), there would be a full 36V drop over the diode. Is that ok if there isn't any current flowing through it? What do you think of...
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