Search found 9 matches

by orion4096
Apr 24 2016 9:57pm
Forum: E-Bike Non-hub Motor Drives
Topic: bosch classic ebike plastic gear
Replies: 28
Views: 10412

Re: bosch classic ebike plastic gear

I haven't been riding my ebike much lately, but I did take it out 5 times a week for several months after the fix with no issues. It still gets used 1-2 times a month. I may be riding it more regularly again if my job relocates.
by orion4096
Nov 06 2015 6:39pm
Forum: E-Bike Non-hub Motor Drives
Topic: bosch classic ebike plastic gear
Replies: 28
Views: 10412

Re: bosch classic ebike plastic gear

I had a half-width gear (to avoid using the mill which cost almost 3x) made out of 7075 aluminum. It arrived late this week and I drilled some tapered holes and bolted it on. Works great. I'm looking forward to riding it to work next week. If I was in the market for a new bike I would definitely con...
by orion4096
Nov 01 2015 10:31pm
Forum: E-Bike Non-hub Motor Drives
Topic: bosch classic ebike plastic gear
Replies: 28
Views: 10412

Re: bosch classic ebike plastic gear

I received the hub adapter from emachineshop. It's machined well and looks like it was done using a waterjet or laser. Unfortunately, my measurements were a little on the loose side so it's not a press fit. I used some JB weld to bond it to the hub and bolted up a nylon and PLA gear this weekend. Bo...
by orion4096
Oct 24 2015 10:29am
Forum: E-Bike Non-hub Motor Drives
Topic: bosch classic ebike plastic gear
Replies: 28
Views: 10412

Re: bosch classic ebike plastic gear

I still need to radius the edges, but here's what I came up with. The inner adapter is being made out of 0.25" aluminum sheet metal with 6 threaded holes for a printed gear to bolt into. There's no convenient way to machine (waterjet?) the part myself so I'm trying emachineshop.com. It's not cheap, ...
by orion4096
Oct 14 2015 9:26pm
Forum: E-Bike Non-hub Motor Drives
Topic: bosch classic ebike plastic gear
Replies: 28
Views: 10412

Re: bosch classic ebike plastic gear

Here's what I came up as test fit for the inner and outer splined surfaces of the gear. I'm tempted to super glue the two pieces together and bolt it together this weekend. Would be interesting to see how long it lasts and what breaks. Long term, I need to figure out a better method than glue to bin...
by orion4096
Oct 10 2015 10:06pm
Forum: E-Bike Non-hub Motor Drives
Topic: bosch classic ebike plastic gear
Replies: 28
Views: 10412

Re: bosch classic ebike plastic gear

I PM'ed as19 (in very poorly written German) about his new hub and gear, but haven't heard anything back, yet. There's also a post in that thread from earlier this year which says he probably isn't making them anymore. I used a little force and was able to get the gear off the hub. Then removed it w...
by orion4096
Oct 08 2015 11:44am
Forum: E-Bike Non-hub Motor Drives
Topic: bosch classic ebike plastic gear
Replies: 28
Views: 10412

Re: bosch classic ebike plastic gear

Thanks for the suggestions. I called the hotline number: - No known spares or service available for classic motor in US. The classic was never sold in the US. - The person confirmed that a shop close to me is a certified bosch ebike dealer/repair place, but didn't think they would be able to help. A...
by orion4096
Oct 06 2015 11:30am
Forum: E-Bike Non-hub Motor Drives
Topic: bosch classic ebike plastic gear
Replies: 28
Views: 10412

Re: bosch classic ebike plastic gear

I contacted a few different ebike shops with no success. Looks like this is going to turn into a project. It shouldn't be too hard to 3d print a new one. I doubt a PLA version will be very durable, but once I have a working replacement part I can find someone to CNC one out of aluminum.
by orion4096
Oct 05 2015 7:58pm
Forum: E-Bike Non-hub Motor Drives
Topic: bosch classic ebike plastic gear
Replies: 28
Views: 10412

bosch classic ebike plastic gear

My bosch classic mid-drive ebike started making a rattling noise at the end of last week. This morning I got on the bike to go to work and the pedals locked up. I opened it up and found a broken plastic gear. Some youtube videos suggest it's easy enough to pull the crank out and remove the gear. But...