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  1. K

    2 speed mid-drive build

    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...
  2. K

    2 speed mid-drive build

    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...
  3. K

    Kawasaki KE100 conversion

    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.
  4. K

    2 speed mid-drive build

    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...
  5. K

    Downhill project motorcycle transmission

    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...
  6. K

    2 speed mid-drive build

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

    2 speed mid-drive build

    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...
  8. K

    Downhill project motorcycle transmission

    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...
  9. K

    Downhill project motorcycle transmission

    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
  10. K

    Downhill project motorcycle transmission

    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 !
  11. K

    2 speed mid-drive build

    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...
  12. K

    First 100% Eco powered vehicle completes a Dakar Stage

    170 kwh?
  13. K

    2 speed mid-drive build

    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...
  14. K

    2 speed mid-drive build

    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...
  15. K

    open source UNIVERSAL quick swap battery

    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.
  16. K

    First 100% Eco powered vehicle completes a Dakar Stage

    He has completed stage 2 also - 530km (about 320miles) of special stage, and reported as being a really tough day for all drivers. Huge achievement. Does anyone know what power unit he is running?
  17. K

    LightningRods mid drive kit

    Check your average speed calc - you won't need as much as 50kph to average 25km/h, if the other half the time you are running at 12.5 km/h. Good luck with the build, nice project.
  18. K

    What would the best full suspension bike be (features)?

    There seems to be a market for a high power almost-motorbike, though riding spaces for those will be hard to find in Europe. Maybe the KTM ride parks will become 'open to any ebike' parks ? The problem I have is that, with respect, no small maker will be able to properly challenge the quality...
  19. K

    Gyro for controlled Wheelies

    The two greatest wheelie exponents in the 70s and 80s were Doug "Wheelie King" Domokos in the US, and Dave Taylor in the UK. The latter is famous for wheelying the entire Isle of Man TT course - that is 37.73 miles. I believe both used a small motor to keep the front wheel spinning while it was...
  20. K

    What would the best full suspension bike be (features)?

    I think there are two distinct (off-road) schools of thought - those who want something with several kW, moving close to an electric motorcycle, and those who want a true mtb that looks and feels like a bicycle, but has a bit more 'go' than the nominally 250W offerings. It all depends on your...
  21. K

    Kona Stinky, no pedals, big block on swingarm.

    Keep going Dave, any project requires that you sacrifice 3 times the expected effort and 5 tomes the man hours and ...er, best not talk about the costs... :D I built a vintage mx bike (not a resto, it was designed and built from scratch), with a pal and swore 'never again' on many occasions...
  22. K

    Let's talk about brakes

    I would definitely take a ride before you buy. I already had hydraulic disc brakes, but have just inherited my sons old bike...that has high end SRAM components and the difference in power, control and feel is frankly astounding. Brakes are not the place to save money, at least if you ride...
  23. K

    2 speed mid-drive build

    Rodgah, thanks for the input. A Honda C90 or similar gearbox may be a good start, my concern was that they are a low power engine (5kW) compared to a race engine like the Kawasaki KX65(11-12kW). It would however certainly be durable enough for my case, maybe not for some of the big power guys...
  24. K

    2 speed mid-drive build

    A frustrating day today. We had access to a milling machine but could not do the machining as planned; we need some additional tooling to accurately machine some of the bearing bores, there are 4 sizes and ideally 2 should be blind. Then tried to work it out on a lathe but ran into different...
  25. K

    Downhill project motorcycle transmission

    I think your motorcycle torque figure at the wheel is actually far higher. Bike dynos measure power at the rear wheel, and an estimated transmission loss is used to correct back to a crankshaft power. Torque is always quoted at the engine speed "xNm at y'000 rpm". Nevertheless, I think you need...
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