Jasonv8z
1 W
Getting ready to order more prototypes. After talking to the factory, they apparently can make a motor with higher copper fill. The standard motor has 11mm of copper (see picture below). I'm told they can wind up to 17.5mm of copper. I'm not sure where they get room in the stator, but I feel it's worth testing out. The downside is these motors are only available in 142mm freewheel / 145mm cassette motors.
To make this motor fit my bicycle, I plan on reducing the brake side axle clearance by 10mm, effectively making it a rim brake only motor. Since the drive side flange is in the same place as a 135mm motor, the drive side spokes should be at the same tension as before. The non-drive side spokes will be lower tension, making this rim less stiff/weaker. It's not ideal, but hopefully it's no worse than a non-powered hub with small spoke flanges.
As an alternative, their new cassette has 8.3mm of threads for the cassette lockring. We could possibly machine away ~4mm from the end of the cassette and still have enough to attach a lockring. You'd lose the smallest cog on your cassette, but gain 4mm of offset to build a stronger wheel.
To make this motor fit my bicycle, I plan on reducing the brake side axle clearance by 10mm, effectively making it a rim brake only motor. Since the drive side flange is in the same place as a 135mm motor, the drive side spokes should be at the same tension as before. The non-drive side spokes will be lower tension, making this rim less stiff/weaker. It's not ideal, but hopefully it's no worse than a non-powered hub with small spoke flanges.
As an alternative, their new cassette has 8.3mm of threads for the cassette lockring. We could possibly machine away ~4mm from the end of the cassette and still have enough to attach a lockring. You'd lose the smallest cog on your cassette, but gain 4mm of offset to build a stronger wheel.