Search found 56 matches

by cozy35
Feb 15 2019 3:58am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

It's strong but it creeps so you'll need to retension it multiple times most likely. It's used for running rigging (which controls the sails) on sailboats but not used for the standing rigging (which supports the mast) for that reason. Likewise it's not used for bowstrings (another hobby of mine). ...
by cozy35
Feb 14 2019 4:00pm
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

You may need a webbing with less elasticity than polyester. Maybe something like HMPE? I'd want some sort of backing so the t-bolt strapping doesn't ride directly on the frame. Both a longer mount on the bottom and some sort of conforming top piece. Polyester Webbing is stronger than Polypropylene ...
by cozy35
Feb 14 2019 9:58am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Here is the in-frame mount setup. Using the same Webbing strap system or T-Bolt setup. This method of mounting does not require BB bracket mounting, simplifying installation. It simply wedges between the seat stay and the down tube. Now, in order to make the Planetary Box End Plates interchangeable ...
by cozy35
Feb 14 2019 5:23am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

tentman wrote:
Feb 14 2019 5:12am
The materiel in bike frame tubes is very thin and a principle I learned in building boat masts was to ensure all "load points" had wide, ideally tapered bearing surfaces . . . I liked your first clamp idea better.
Yep, that is what I will use on carbon frames.
by cozy35
Feb 14 2019 4:11am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

So, the hint for the T-Bolt solution inspired me to come up with this neat mounting style. It is low profile, functional easy to make. A simple flat laser cut band with slotted ends and bent to shape.
80P-Assembly-Fit-New.jpg
80P-Assembly-Fit-New.jpg (51.81 KiB) Viewed 111 times
by cozy35
Feb 14 2019 1:43am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

I REALLY like that! I've thought about using T-bolt clamps plus some sort of backing material in a similar way. Thanks for the tip. I never even thought about that. A good backup material would be clear Poly Carbonate Sheet - this then for metal framed bikes. When it comes to carbon, I still believ...
by cozy35
Feb 13 2019 5:33am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Here is the assembled example as mounted to the down tube. Not showing the BB at this stage.
SaddleFit.jpg
SaddleFit.jpg (48.85 KiB) Viewed 145 times
by cozy35
Feb 13 2019 5:26am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

I have been toying with an effective mount that will not destroy carbon frames. For that I steered away from conventional U-Bolts and metal clamps. Carbon frames do not take kindly to these methods. I decided to use Polyester Webbing Belt material for this. It will also protect paint finishing and n...
by cozy35
Feb 12 2019 2:45am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

The BB mounting plates and a remodeled Box End Plates are done, and now for the saddle to down tube mount. I think I will have to make a spreadsheet to determine the various required spacers to cater for the different BB spindle sizes. The saddle mount should be a universal fit for down tubes from 3...
by cozy35
Feb 12 2019 1:02am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

You might not have enough motor for the sustained output you're after. You could easily mount the gearbox under the downtube and motor above. It's much more compact than your original series of belted pulleys. I don't believe that this setup would ever exceed 3000 Watts. The motor I am using is rat...
by cozy35
Feb 12 2019 12:44am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

OK, so I've moved on and started to design the mounting. Hopefully I can come up with an ergonomic system easily adaptable to a variation of down tube sizes in both steel, aluminum and carbon fiber. I would like to have both a non- bottom bracket and bottom bracket mount system. I think I can do thi...
by cozy35
Feb 11 2019 3:58pm
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Rather than coupling onto the end of the motor you could run a belt or chain drive to the gearbox. This would let you run a bigger motor without being overly wide. The PlanetBox plus Motor totals 116MM Plus the 14.9MM for the freewheel sprocket. So from end of motor to center line of the sprocket i...
by cozy35
Feb 11 2019 3:23pm
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Grantmac wrote:
Feb 11 2019 1:23pm
With the correct input and output support one of the single stage would make a great jackshaft. You could run a 2:1 drive into it for excellent belt/chain life.
Not sure I follow?
by cozy35
Feb 11 2019 11:23am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Hello again - do Banebots have data online about the ratings of their gearsets - I can't find it . . . where/how did you get the specs (I want the specs of their bigger offerings). Thanks No they don't. It is stated in the fine print in the product description. It is still strange to me why the alu...
by cozy35
Feb 10 2019 4:33am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Before you wrote the gear set is capable 160NM. Any deadlines when the mid drive set will be made? Do you prefer making it for yourself only or as GB? I used the hypothetical number of 160NM as a result of my findings and experience with this gear-set. As I indicated that Banebots say it should not...
by cozy35
Feb 10 2019 12:22am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Hello - interesting ideas. Do you have a reference for the allowable torque on the outside end of these Banebot Planentries (I can't find one), and which model are you considering. Thanks I am referring to the P80 model parts. I am only using their planets/sun/spur and ring gears, and not the beari...
by cozy35
Feb 09 2019 12:50pm
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Make sure that you keep the conductive materials away from the shell of that outrunner. A lot of motors oversize the magnets and under size the back iron as a weight optimization, and leak alot of flux out of the can when they do it. The flux leakage induces some serious heating in anything conduct...
by cozy35
Feb 09 2019 12:45pm
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Perhaps better to use APS8072 50KV for enough power without too much heat build up. With planetary reduction gear you can reconsider belt drive or direct belt left side drive. Also freewheel should be implemented to the motor. Chain combined with planetary gear will produce too much noise from the ...
by cozy35
Feb 09 2019 12:41pm
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

Grantmac wrote:
Feb 08 2019 3:14pm
Will it fit between the cranks?

I have designed tot to fit between cranks with spindles 92MM and up and a Q-Factor 0f 145 and more.. It it does not fit between the cranks one can fit it outside the pedal arc.
by cozy35
Feb 08 2019 10:24am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

Re: New Approach to 4500W Mid Drive

An exploded view of the assembly.
P80-M-Box-IPN-001.jpg
P80-M-Box-IPN-001.jpg (45.68 KiB) Viewed 781 times
by cozy35
Feb 08 2019 5:14am
Forum: E-Bike Build Threads / Photos & Video
Topic: 4000W Compact Mid-Drive Build
Replies: 8
Views: 666

Re: 4000W Compact Mid-Drive Build

OK, so I have decided that reduction drives built out of synchronous belts and pulleys is not the way I want to go, simply because I cannot justify reliability. It just seems that you will forever spend time on maintenance. My new drive thread is here: https://endless-sphere.com/forums/viewtopic.php...
by cozy35
Feb 08 2019 5:11am
Forum: E-Bike Build Threads / Photos & Video
Topic: New Approach to 4500W Mid Drive
Replies: 36
Views: 1134

New Approach to 4500W Mid Drive

After me previous plan for a compact, light weight mid drive, suffice to say that the synchronous belts and pulley system turns out to be a little more problematic in the way of reliability and torque handling. My previous post: https://endless-sphere.com/forums/viewtopic.php?f=6&t=98510 This is my ...
by cozy35
Feb 04 2019 11:07am
Forum: E-Bike Build Threads / Photos & Video
Topic: 4000W Compact Mid-Drive Build
Replies: 8
Views: 666

Re: 4000W Compact Mid-Drive Build

Fastest1 wrote:
Feb 04 2019 9:57am
120 rpm is pretty easy to maintain. Just have to spin an easier gear.


Sent from my iPhone using Tapatalk Pro
Yeah, but at the top end that this motor/ratio combo is capable of, (165 RPM) will require a freewheel crank.
by cozy35
Feb 01 2019 11:12am
Forum: E-Bike Build Threads / Photos & Video
Topic: 4000W Compact Mid-Drive Build
Replies: 8
Views: 666

Re: 4000W Compact Mid-Drive Build

So what you're saying is that 100W of heat must be dissipated to be safe? (in the case of a SK3 6374 149KV) This motor is rated 4000 Watts and at most in this case the motor will draw 58 A @ 2150 Watts. I take it that efficiency is lost by way of heat? I have seem some guys 3D printing a centrifugal...
by cozy35
Feb 01 2019 8:40am
Forum: E-Bike Build Threads / Photos & Video
Topic: 4000W Compact Mid-Drive Build
Replies: 8
Views: 666

Re: 4000W Compact Mid-Drive Build

Here is an example of under the down tube with side plates to the bottom bracket.