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by dequinox
Mar 25 2020 11:35am
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

Ok, I managed to put together the painted bike frame and Xtracycle sub-frame... I'm liking the look so far! I'm waiting on a headset and a bottom bracket to come in, then I'll put the fork and crank on.
Painted xtracycle.JPG
Painted xtracycle.JPG (137.17 KiB) Viewed 139 times
by dequinox
Mar 20 2020 8:37am
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

Fiiiinally got my frame and free radical painted. The frame is painted an olive drab with a touch of forest green in it. I've powder coated the free radical and fork black texture. Came out quite nice. I'll have to post the photo later today, as i cannot seem to get my phone to downsize the pic enou...
by dequinox
Mar 16 2020 1:52pm
Forum: E-Bike General Discussion
Topic: Giant cruiser budget build
Replies: 95
Views: 9874

Re: Giant cruiser budget build

I had a question on an old battery pack, LiFePO4, wherein I have a BMS I've been feeding the 54.6 v from a Li-ion charger, where most of the resting cell voltages are within 0.27v of eachother, but the ground to cell-1 readout is 2.47. That's got me a bit worried. I've got it wired such that the red...
by dequinox
Feb 26 2020 1:32pm
Forum: E-Bike Technical
Topic: "Steer Tube" Alum. Weld Repair
Replies: 13
Views: 670

Re: "Steer Tube" Alum. Weld Repair

Whoa folks it's not as if I've made this thing already! :lol: I realized it was far longer than it needed to be. The original part was only like 6.25" long. I'm just spitballing here, and I've got to get a line out to giant to see what parts they still have. This now has 150% of the tube diameter......
by dequinox
Feb 25 2020 7:06pm
Forum: E-Bike Technical
Topic: "Steer Tube" Alum. Weld Repair
Replies: 13
Views: 670

Re: "Steer Tube" Alum. Weld Repair

Well this just became a bit of an engineering project. I started looking at woven carbon fiber tube... oops.
Here's the boss on the hinge that my busted part was pressed on:
Hinge boss dimensions.jpg
Hinge boss dimensions.jpg (118.27 KiB) Viewed 558 times
Next, the design of the new part:
New Steer Tube.jpg
New Steer Tube.jpg (48.88 KiB) Viewed 558 times
I'll digress for the time being. :roll:
by dequinox
Feb 25 2020 4:36pm
Forum: E-Bike Technical
Topic: "Steer Tube" Alum. Weld Repair
Replies: 13
Views: 670

Re: "Steer Tube" Alum. Weld Repair

you should've said that to start with, ... don't try "fixing" the existing one and riding with it. I'm going to examine it more closely, but what I was referring to was the micro-cracking evident in the finish (what I assume to be plating... doesn't really share characteristics of anodizing). See p...
by dequinox
Feb 25 2020 3:34pm
Forum: E-Bike Technical
Topic: "Steer Tube" Alum. Weld Repair
Replies: 13
Views: 670

Re: "Steer Tube" Alum. Weld Repair

Hmm, sounds like this might be a misguided undertaking. I was 90% sure I wanted to redo the weld anyway. I've seen some other evidence of cracking in the part as it is, so we may be headed for a new part. I'd like to upgrade it, so we might be in for engineering a new piece. CF layup, anyone? :lol: ...
by dequinox
Feb 24 2020 6:40pm
Forum: E-Bike Technical
Topic: "Steer Tube" Alum. Weld Repair
Replies: 13
Views: 670

"Steer Tube" Alum. Weld Repair

Not strictly e-bike related, but I could use some input from frame-builders here. For reference this is a giant expressway. I ended up cracking my folding bike's "steer tube", which by this term I mean it's the telescoping/folding tube section which press-fits/glues onto the folding hinge. Please se...
by dequinox
Jan 22 2020 11:50pm
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

This design allows for the "bus bar" to stick out both ends, and allows nickel strip of varying thicknesses if someone wanted to do higher amp discharging. I don't have any data on what the discharge capacity of this design is yet... I just began printing the first one tonight. You can see it in pro...
by dequinox
Jan 22 2020 5:40pm
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

So I've got most of this frame stripped down and blasted, getting ready to paint it. On another note, I'm developing a couple different 3d-printable 18650 cell holders. Just for fun, here's a preview. I didn't want to start a whole new thread on it until I've done some testing. The first is for arra...
by dequinox
Sep 27 2019 9:36am
Forum: Battery Technology
Topic: Lipo Charging Box
Replies: 2
Views: 358

Re: Lipo Charging Box

Indeed. Time for a 5V 40A meanwell :flame: :kff: :pancake:
by dequinox
Sep 20 2019 9:37am
Forum: Battery Technology
Topic: Lipo Charging Box
Replies: 2
Views: 358

Lipo Charging Box

Just a quick project that I completed in less than an hour... easy to do if you have access to soft fire brick. I acquired a free metal file box, and had some fire brick laying around from my blacksmithing activities, so I whipped this up: https://i.imgur.com/zKrDnDF.jpg https://i.imgur.com/Z3inSML....
by dequinox
Sep 06 2019 12:23am
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

Essentially yes, but there's fewer of them. I might try to mix and match to get a good set then send back the crap. I haven't returned the original to an Amazon drop site yet. :mrgreen:
by dequinox
Sep 05 2019 11:07pm
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

Well the replacement set of disc brakes showed up with chips in it's adjustment wheel too. I'm just going to live with it for now and leave a bad, but accurate, review once I've felt how they work. I managed to score another 26" front kit with a tired old lifepo4 battery locally for $50, and some bu...
by dequinox
Aug 29 2019 12:48pm
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

I received some disc brakes from Amazon yesterday, and they arrived slightly broken, so I'll have to return and get a new set. However things are moving along nicely... I way over-paid for a set of t-nuts and bolts to attach the free radical to the bike frame ($27 with shipping... holy ****). https:...
by dequinox
Aug 29 2019 10:32am
Forum: E-Bike General Discussion
Topic: Giant cruiser budget build
Replies: 95
Views: 9874

Re: Giant cruiser budget build

dequinox, any updates on your project? I haven't updated in a while because I've had other project come to the forefront, and it's been a terribly busy summer. I still have the following left to do: battery box, 18650 pack, powder coat rear rack (pick a color to boot :roll:), cut custom torque arms...
by dequinox
Aug 20 2019 10:10am
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

Got my fork in, and the dropouts are a little strange, but I think this is on purpose: https://i.imgur.com/kqWBIVR.jpg Pieced it together for a gander at the overall look: https://i.imgur.com/tOLLfq0.jpg Noticed the xtracycle dropouts are a little tight for this hub motor, but I think I can stretch ...
by dequinox
Aug 13 2019 9:50am
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

Ok I'm up a fork, and it's on the way. I found one on ebay, and managed $62 for it. I am sure there may have been cheaper options, but I'm ok with it since it has the disc bosses and a fairly long steer tube. Hopefully it's a good fit for this build. I'll re-coat it green along with the rest of the ...
by dequinox
Aug 08 2019 11:38am
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Xtracycle Build Log

Last night I cobbled together the frame and freeradical (FR from now on), just to get a feel for the size of it. It's a '92 Giant Sedona frame, the free radical (FR), and I'll be robbing components off my first build from 2009. The fork was close, but the steer tube was not long enough. Beyond that,...
by dequinox
Aug 05 2019 10:14pm
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Giant Frame w/ Xtracycle Build Log

Thank you, now that's helpful. I was trying to do some reading on it, kept getting distracted by... You know... Work. 😁
by dequinox
Aug 05 2019 12:34pm
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Re: Giant Xtracycle Build Log (Stokemonk-ish?)

OK next issue. Steer-tube size and headset selection: I have a 7in dimension from top bearing race to the bottom. The ID of the frame head tube is about 1.3", give or take about .030". How do I tell what steer tube diameter to use? It seems to me this would technically fit a 1 1/8" steer tube, but I...
by dequinox
Jul 31 2019 10:51pm
Forum: E-Bike General Discussion
Topic: Failure Analysis of a Cracked Frame - Recommended Steel Cruiser (Feet Forward) ?
Replies: 22
Views: 1008

Re: Failure Analysis of a Cracked Frame - Recommended Steel Cruiser (Feet Forward) ?

Oops, just realized i double posted that...
A new frame is probably far better a choice now that I'm thinking on it. Those Worksman bikes look nice.
by dequinox
Jul 31 2019 10:51pm
Forum: E-Bike General Discussion
Topic: Failure Analysis of a Cracked Frame - Recommended Steel Cruiser (Feet Forward) ?
Replies: 22
Views: 1008

Re: Failure Analysis of a Cracked Frame - Recommended Steel Cruiser (Feet Forward) ?

If you attempt to salvage that frame, cut out that gobshite top tube, and replace it with a good chunk of like 1 1/4 by 2 by .065 or maybe .080 wall rectangular tube, have a metal shop till it to the rough shape of the old one and weld it in for you. Probably cost you about as much as a new frame.
by dequinox
Jul 31 2019 7:10pm
Forum: E-Bike Build Threads / Photos & Video
Topic: High performance & durability Cannondale Semi Recumbent
Replies: 279
Views: 26204

Re: High performance & durability Cannondale Semi Recumbent

I'm not super clear on what your goals for the recumbent are (I may have read a while back but don't recall entirely, other than durable on pothole roads and fast 40mph or so), and don't know if you've already thought about it, but here's a throwback to Justin's trans-Canadian rig . It has a semi-re...
by dequinox
Jul 31 2019 12:08am
Forum: E-Bike Build Threads / Photos & Video
Topic: Xtracycle Build Log
Replies: 15
Views: 1962

Xtracycle Build Log

I acquired a giant frame a while back (probably over 2 years ago, $15), with the intent of incorporating it into some sort of cargo-bike build. It's steel or chromo, and is rather large (maybe 20" seat tube). Well today I spotted this little gem: https://i.imgur.com/XVTizGr.png So I went, I saw, I h...