Endless Sphere

Hi Adam, Well done getting the bike going so quickly.. looks as though it goes very well and would be huge fun to ride. Good to hear that the motor goes as well as hoped, but a bit worrying about the heating. It will be interesting to hear how it goes on longer rides, and how efficient it is. Quite ...

Great to see it is up and running! Well done! Are you still having issues with low speed cogging / poor startup? If so, it could be a hall effect sensor issue. I'm not experienced with brushless motors, but have been doing a lot of research lately, and this description matches issues others have had...

More progress: The pivot bolt is finished and two 10mm wide spacer bushes are welded to the inside of the front swingarm brackets to set the width of the swingarm. 2014-05-11 16.41.05.jpg The outside width of the swingarm bearings in their modified housings ended up at 98.3mm, narrower than I had ex...

Definitely keen, PM sent.

Hi Stevil, Do you have any of the twin disc hubs left? If so: What diameter is the axle, and is it a through axle that can be removed, or is it trapped in the hub, so needing slotted dropouts to fit the wheel? Looks like 36 spokes.. is that right? I am thinking of using one as a rear hub on a reason...

We had a great holiday, but we are home again and it is time to make more progress: my friendly local bike shop donated two external bottom bracket housings with worn bearings, and I have removed the original bearings and pressed in my adapter sleeves and 6202 bearings. 2014-05-01 20.08.54.jpg As yo...

Hi Skeetab, Glad I found this thread. I am doing something similar at the moment using the same motor ( http://endless-sphere.com/forums/viewtopic.php?f=28&t=58313&start=25 ) with a purpose built swingarm on a Kona Stinky, but without pedals. You have already answered a few of my questions a...

More progress: I have made the front brackets for the swingarm and tacked them on in the same way as the rear brackets. 2014-04-16 18.38.52.jpg Swingarm trial fitted to the frame. I have left it longer than needed at this stage.. I have been given a 26" x 3" tyre and tube, and am having pr...

Swingarm Pivot bearings: As mentioned previously, I am using the bottom bracket of the frame as the swingarm pivot. I will use standard external bottom bracket bearing housings, but the 6805 bearings used are not as robust as standard 6202 bearings, and cost more. I decided to use 6202s, but their o...

Ok, time to make some decisions and spend some money.. Motor: Definitely the low kV "Big Block Alternative" nominal 48V 1000W brushless as sold by BHT; Definitely a V3 Cycle Analyst to gather information and possibly assist in throttle control; Controller: Kelly KBS; Batteries: Here is whe...

2014-04-11 15.49.27.jpg I found another half hour, so managed a bit more progress. Welded angle braces to top and bottom of the back axle brackets, squared off the back of the brackets, then cut the tack welds to separate them. 2014-04-11 16.09.09.jpg The reason I tacked them together while making ...

plz dont talk about mass, plz talk about " rotational inertia". That would be the exact term, at least for a 2-linker. Sorry drum i thought you saw this thread.. otherwise i would have told you... good luck with your built i am waiting for results and proceed with my own then i built/repa...

Hi everyone, I am really liking this thread. Lots of opinions, lots of apples being compared to oranges, with a few bananas and avocados thrown in.. especially at the beginning. Hub motors, motors on swing arms and frame mounted motors all being compared.. but things seem to be settling down and a l...

Nice machining on the crank arm to mount the freewheel!
Great job getting the mechanisms sorted out.

Maybe a chainguard on the primary drive, before it eats your trousers??

Ok, I have found ( or manufactured) another hour of usually non-existant spare time, so the real build has begun. Real life is demanding, and does not leave me many minutes per week of project time, so this build may not be the quickest on record! This is one of the reasons I have decided that thing...

I am ready to order one also.. It would be really nice to have confirmation that it lives up to expectations. Hi BZH, I've been following your impressive builds for a while. I'm interested to see you are going for a Kelly controller.. I was thinking of going that way too after advice from Crossbreak...

Hi Paul,
In one of the photos you are machining what appears to be the motor shaft, with the magnets exposed. If I am right, is there any problem with swarf sticking to the magnets?
I had assumed that it would be an issue to keep the magnets clean.
Thanks,
Dave R

Yes, but you don't have to use the whole width of the cassette. Most of my Shimano cassettes have the biggest few sprockets pinned or welded together, but the smallest 3 or 4 are loose, so by leaving the loose ones off, the pinned unit could be slid outwards and the sprocket connected to the back of...

Hi Paul, thanks for the info. I still have packs of brazing rod bought 40 years ago (my grey hairs are multiplying when I realize that!), in good condition, that I still use occasionally. Although they do have a bit of zinc in them there was more tin, so it is interesting to hear that there are allo...

s. Later, the brass welds can be sanded perfectly smooth for an incredibly beautiful finish. Hi Ron, Great article on this nice bike. One correction however, brazing (despite the name) uses BRONZE rod, not brass, as the filler material. Bronze is stronger and more corrosion resistant than brass. Ma...

My small lathe can swing a diameter of 255mm over the bed, and my big one can swing a 16 inch 4WD rim with room to spare, so I am not limited by size in terms of bicycle components! Yes, I think using a worn out cassette in some way to mount the sprocket is the right way to go. If the sprocket is st...

Yes, I intend to move the motor for chain tensioning, Either the motor or the wheel has to move, and the chain puts equal and opposite forces on them. However, the back wheel also takes the weight, traction and braking forces, so I am going to simply drill 12mm holes accurately opposite each other f...

Hi Dirkdiggler, Its definitely a Stinky, but an early one. The previous owner said it was a 2003 model... I don't know if that is correct, but they did change a bit over the years so the more recent ones do look a bit different. Yes, it will need a guard over the sprocket.. I don't fancy the thought...

Hi Crossbreak, to answer a couple of questions you asked earlier: nice! using the BB as pivot makes sense. you coult use HT2 bearings and a 24mm shaft ....what do you think? this would widen your bearings... i dont know how wide your original ones are.. you would get a width of 100mm or so with the ...

Hi K-ray, Thanks for that. It is sometimes worth paying more to deal with a "known" supplier who has done their job well in the past, and it seems that this supplier has done ok for more than one of you.. The cheapest I have found is this: http://www.mistertao.com/beta/pages/item/362661846...