Endless Sphere

I've been rebuilding 2 MACs for my AWD Fatty . Standard Stator and runner, standard gears (but greased with Aeroshell), and with a beefy clutch (up to 170Nm). It has a side entry motor cable and internal gear & temp sensor. Heavy duty use, so far no problem. Been tinkering with the idea of a 2-speed...

Regarding the CA, it seems almost impossible to gather and route somehow the short JST cables into a sealed box. Also, there is just no space on the handlebar of a bike for doing that. The solution must be service-able one, in case any debugging/connector replacing is necessary. If your solutions a...

The seal lip is running on that bush. And you probably have to install a complete new wire to get your problem fixed.

The potting compound is called 'magic rubber', it's a 2-component mix and supplied by Raytech.

In SETUP PAS SENSOR shouldn't the P and D arrows move up and down? Only the D arrow moves up and down if I turn the pedal by hand. If I disconnect the PAS signal and connect Speed/Direction to the PAS solder pad, then the P arrow goes up and down. already were there in this post on page 154 https:/...

8T MAC on a 26" rim with 4" tyres? Why 8T?

Hi all, I keep getting enquiries as to when I release a CA3-Phaserunner combo with HIGO connectors on the phaserunner and a plug&play set of cables for the BBSHD. The idea was to get some 'raw' phaserunners from Justin, wire it up with HIGOs and then encase it in epoxy. Justin so far is happy to sup...

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Take a Surly Ice Cream Truck, add some MacFats and 1900 Wh of battery and you get this:
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I wish pressing Bafang worked. The BBS02B landed on Luna shelves without any notification of a change. It took a couple of years and another reseller in China to get a decent part supply chain. If not for this site and the fella,s posting, we,d be SOL. ES made Bafang and they remain aloof. The more...

The CA3 with Higos is on his website. The CA3-HIGO is more or less the standard CA3-DP/DPS upgrade. It is NOT suitable for use with BBSx controllers. With an adapter (HIGO to JST) you can use a CA3-HIGO with the Phaserunner. A full CA3/Phaserunner set (including plug and play harness) will be avail...

I don't understand the "no axle channel" part . Gotta get the wires in there somehow. At some point, all hub motors have an axle channel. Usually it is after the bearings behind the side covers. They dont' *have* to have an axle channel--that's what I was talking about before. If the bearing's ID i...

Turn the square by 45 deg to improve clamping

e-beach wrote: ↑

Apr 05 2018 4:58pm

Dovetail groves, that's what I was thinking about.

Yep, dovetails. That's what I meant with 'negative angled grooves' in my earlier post.

If the motor cable connector was installed after the torque arm was on the axle, then you could get away with just a small curve to accomodate the cable. But if we want it to work with one of these L1019 Overmolded Connectors then either we need a 19mm diameter open circle in the torque arm that th...

Tommm wrote: ↑

Apr 05 2018 3:39am

Is there a way to get PAS working on the phaserunner?

By utilising the BBSHD's original PAS/DIR sensors, the CA3 evaluates these signals and controls the Phaserunner via the PAS-setup menu.

OK, meet the new CA3-CX (Custom whatever)...
Here the CA3-CX with a Phaserunner CX on the BBSHD. All plug and play.
and here in more detail as PDF file:
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I'm looking forward to how the torque arm supports itself on the other end against the frame...

To connect a standard CA3-DPS with a standard Phaserunner and a standard BBSx you would need 5 adapters : 1. a throttle adapter to connect your BBSx throttle with the CA3 2. a brake adapter to connect your BBSx brakes with the CA3 3. a PAS adapter to connect your BBSx PAS sensor with the CA3 4. a ha...

Maybe if it's so poorly made that the covers only center the rotor on the stator in one position, and allow the rotor to rub on the stator if it's not installed the same way it was originally built. That used to be a major problem with the early Crystalyte H-series. That and the rubber seal ring ru...

2 flats on an axle is OK, when the torque arm is used the correct way. Here a torque arm fitted with a Crystalyte HS3540: . torque arm forward.JPG . The torque arm is made from 4 mm thick alloy 7075 T6 and is used with 4 additional torque washers: . torque washer.JPG . They are connected with 2 piec...

...what was happening is that once the first tooth broke off on the plate, the entire axle was then able to 'walk down' as it was being rotated and into the cavity of the torque arm plate where the wire exit would normally be located. ...a squashing the cable in the process = back to the drawing bo...

Hi all,

in the meantime I had a chat with Justin and I might get some unpotted phaserunners without any wiring attached.
So the options at this point are wide open, and I'll prepare some documentation regarding possible wiring. Could you give me some kind of idea of what you would prefer?

Reinhard

Excellent Jig - I'm looking forward to see the graphs.

Hi,
got a brand new one here, without gears, EUR 30 incl shipping to Österreich

Have not heard back from Justin, so I guess he is not interested in making a batch of phaserunners with HIGO connectors casted in.