Search found 831 matches

by APL
May 17 2021 7:35pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

Progress is slow,.. the swing arm, mount, & shock mount all have to get built together more or less, and clamped to the frame so I can sit on it and check the fit. Seat position.jpg At least I have that done, and the swing arm is on the way to being completed. Lots of steel to be trimmed off yet...
by APL
May 17 2021 12:46pm
Forum: EBike Build Threads
Topic: Fat-Covid ebike conversion
Replies: 17
Views: 659

Re: Fat-Covid ebike conversion

Awesome battery project, and truly inspirational! :thumb: When the time comes, I'm going to borrow all your tricks and build a similar pack for myself,.. thanks for sharing all the info and ideas! One question I have on the Daly BMS your using,.. a tried and true unit? I've seen it around and was cu...
by APL
May 13 2021 8:01pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

Well, I've changed my mind on the side plate a few more times, so who knows... now I'm thinking instead of trying to hide the box, maybe I should feature it with a little fear factor. :bolt: I have the rear mid tubes and bridges in, so the frame skeleton is complete, and now it's all about brackets ...
by APL
May 09 2021 6:50pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

Finally have the front mid-tubes brazed in,.. after quite a bit of effort. Have to say though, it looks to be a massively strong front end. Front mid-tubes..jpg And a shot of the bike with the wheels on it. I don't know what kind of tires will eventually wind up on it, I might even opt for a 29er on...
by APL
May 05 2021 8:13pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

Thanks guys, it's starting to look a little dangerous! :thumb: Not quite ready for a post, but I'll show what I have anyway. Summer has a way of splitting your time in five different directions, plus, I'm in a fairly hard part of the build. These girder frames have a multitude of connections in one ...
by APL
Apr 30 2021 8:53pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

Couldn't resist finishing out a ring joint, to see how it will look. Fillet brazing is a lot of work for sure, but it can look sweet! All that will come towards the end though, just before paint. Finished ring joint..jpg The battery box bridge looks like it's bullet proof! I'm pretty sure that these...
by APL
Apr 29 2021 12:54pm
Forum: EBike Build Threads
Topic: Hub motor as mid (illegalbike)
Replies: 17
Views: 1491

Re: Hub motor as mid (illegalbike)

Awesome thread, beautiful pictures, excellent build! Really turned out nice! :thumb: :thumb: :bigthumb:
by APL
Apr 26 2021 8:01pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

I have the J tubes brazed in, and have a pretty good idea of what the ring miters should look like now. If I make the flute about 55mm long, it puts the 10" ring at 90 degrees, so that makes it easier to file the rest of them. Flute = 55mm.jpg The ring didn't turn out too bad, and I'm happy wit...
by APL
Apr 23 2021 1:08pm
Forum: Bike Mechanical & Structural
Topic: Frame building fixtures.
Replies: 12
Views: 545

Re: Frame building fixtures.

I think your right, the horizontal 4x4 rails as a base, and able to insert wheels is a grate idea. Gives you a nice base for all the other add on's, and can be more universal. Being able to put the wheels in while your building is a super good idea, like you say, wheels, chainline, and length is que...
by APL
Apr 22 2021 6:12pm
Forum: Motor Technology
Topic: DIY Toroidal Axial Flux PM
Replies: 99
Views: 2542

Re: DIY Toroidal Axial Flux PM

I've used paint stripper to clean the enamel off of multi strand ends, if your in a pinch or a tight spot. Harsh chemicals are no fun, and you have to squirt it and toothbrush it off, but there it is,.. another option. That old solder pot can be hard to reach sometimes. Not all paint strippers are t...
by APL
Apr 22 2021 5:38pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

All fluxed up with some GFM type ’B’ bronze brazing flux, and it’s ready to go. GFM type 'T' bronze flux..jpg After a some torch work, and a lot of brass, she's stuck together but good. It's good to build it up a little, so it will finish out nice. Head tube brazed..jpg Finally, it’s a frame! One mo...
by APL
Apr 21 2021 1:14pm
Forum: Motor Technology
Topic: DIY Toroidal Axial Flux PM
Replies: 99
Views: 2542

Re: DIY Toroidal Axial Flux PM

It's hard to judge the size and strength of your stator, but maybe some kind of mini-clips to temporarily hold things in
place?
Mini clips..jpg
Mini clips..jpg (12.3 KiB) Viewed 318 times
by APL
Apr 19 2021 8:19pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

I decided to put the top tubes in, as long as it's in position, which was a lot of messing around. Four tubes will help keep the head tube from moving around when it gets brazed. Tubes mitered..jpg This frame is making me get creative with the clamps. Some vent holes, and just a few more tweaks here...
by APL
Apr 17 2021 1:54pm
Forum: Bike Mechanical & Structural
Topic: Frame building fixtures.
Replies: 12
Views: 545

Re: Frame building fixtures.

Thats awesome LewTwo, lots of ideas there. Those guys that are bonding frames have it made! Glue it together and watch
it dry. :wink:

Man, I didn't know that bamboo was that thick!
by APL
Apr 17 2021 1:36pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

Its a Manards item, but generic and several companies re-lable it. Stay away from the Harbor Freight piece of junk. When the smaller roller is used, the length gets out of range for the belt sander, so thats an issue that I need to fix. Not sure how to go yet, I might cut a section out of the middle...
by APL
Apr 16 2021 7:24pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

No frame yet, but getting close. I took a few days to build a tube mitering machine from a cheap belt sander. I changed out the top roller with a 1.5" spool. Takes a little effort and still needs work, but it's working good for now. IMG_2683 .jpg I have a set of fancy Ti coated hole saw cutters...
by APL
Apr 16 2021 2:15pm
Forum: Bike Mechanical & Structural
Topic: Frame building fixtures.
Replies: 12
Views: 545

Re: Frame building fixtures.

I could see the instagram photos, but I couldn't copy one, and I worry about copyrights, so we'll have to find one like it. A very nice fixture though, and looks like it will work very well. I think about making one similar to that often, and I like the easily obtainable square tubing aspect of it. ...
by APL
Apr 16 2021 1:23pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1477
Views: 132471

Re: APL's DIY axial-flux motor

Yea, cash is tight, with so many projects going on all the time,.. if I just stayed in bed I'd be rich! :wink: I'll just sell something that I'm not using, when the time comes, and get something decent, like you say, "You get what you pay for". I'll get back into the ring soon enough, and ...
by APL
Apr 15 2021 8:35pm
Forum: Motor Technology
Topic: DIY Toroidal Axial Flux PM
Replies: 99
Views: 2542

Re: DIY Toroidal Axial Flux PM

You guys must drink a lot of coffee,.. I have trouble just keeping up with this thread! :shock: I guess I'm not really sure what your having trouble with, on the wire moving or not staying put, but it's common for motors to use string to help hold coils together. Theres a fabric fishing line thats s...
by APL
Apr 15 2021 7:38pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1477
Views: 132471

Re: APL's DIY axial-flux motor

Yea, I'm looking into it, but my battery supply is pretty meek at the moment. And looking through controller's, trying to balance 'want', and 'need', is difficult. Most of my motors are sensorless, and most of the FOC controllers are hall. It would be nice to have programable FOC for motor building,...
by APL
Apr 15 2021 2:04pm
Forum: Bike Mechanical & Structural
Topic: Frame building fixtures.
Replies: 12
Views: 545

Re: Frame building fixtures.

The problem with most diamond frames, is that they are a road bike design first, and make a poor conversion to e-bike. No place for batteries, direct drive only, and the dropouts aren't made for big motors, nor are they made for the extra weight and speed. Same goes for many of these fixtures,.. roa...
by APL
Apr 15 2021 1:42pm
Forum: Bike Mechanical & Structural
Topic: Frame building fixtures.
Replies: 12
Views: 545

Re: Frame building fixtures.

I'll kick it off with this three part link, while I dig around for photos of some others that I have seen, or used. https://www.mtbr.com/threads/a-small-contribution-about-frame-jigs.890411/ https://fernandoj.wordpress.com/2013/12/31/bicycle-frame-jigs-23/ https://fernandoj.wordpress.com/2014/02/14/...
by APL
Apr 15 2021 1:06pm
Forum: Bike Mechanical & Structural
Topic: Frame building fixtures.
Replies: 12
Views: 545

Frame building fixtures.

Thought I'd open up a thread on fixtures of various types and designs, frames, forks, whatever. Pictures, links, parts, anything fixture. Just to get this stuff in one place so people can get ideas on the good, the bad, and the ugly. It seems that there is no such thing as a perfect fixture, they al...
by APL
Apr 15 2021 12:45pm
Forum: EBike Build Threads
Topic: APL's V4 Cruiser Build.
Replies: 32
Views: 1559

Re: APL's V4 Cruiser Build.

Thanks shirk, yes fixtures,.. they are varied and many, it seems there is no such thing as a perfect fixture. I've seen a multitude of them in my day. I settled on the table-tacking fixture way back when, and never changed it. Originally it had big electro magnets that clamped the tube holders down,...
by APL
Apr 13 2021 1:23pm
Forum: Motor Technology
Topic: DIY Toroidal Axial Flux PM
Replies: 99
Views: 2542

Re: DIY Toroidal Axial Flux PM

Super awesome thread HalbachHero! My hat goes off to your tenacity and ingenuity,.. which is what it takes to do this DIY stuff. Lots of sleepless nights, he, he... :wink: Now I can see what your up to, great pics, and I can see that the trail of tears has been long and hard. I love the 3D printing ...