veloman wrote:I have read the first 11 pages here, and I realized something.
You only need the freewheeling cog for the pedal drive chain, not the motor driven one. This is because you should be able to easily bolt your large chainring onto the back of a 7 speed cassette (which is obviously already splined). You don't need the motor sprocket to freewheel unless you really need to pedal the bike without motor drag.
Pedaling with no motor drag is exactly what we like.
No compromises drivetrain.
The remaining issue is getting your cheap freewheeling sprocket on the splined hub. But to me, it should be less of an issue since it won't require as much of a quality interface as the motor one would need - just enough for whatever small amount of pedaling you will do.
Do you have any ideas for making getting a cheap freewheel onto the splined hub??? We compiled some of the best minds on this forum together for weeks trying to solve that very problem. If you've got a clever alternative, please share it with us!!!
OR, you could solve this whole problem by using freewheel cranks, which are only like $50 with chainrings at sickbikeparts.
-Motor drive freewheels with splined cassette.
-Pedal chain spins with motor, but freewheel cranks allow you to coast.
-Pedaling with motor off will have some drag, but who really pedals a high powered ebike with the motor off? I do a little on my current low powered rig, but that's at 8mph in parking lots. It's a non-issue IMO.
What do you guys think?
Then you're back with your bicycle chain and front chain-rings spinning at 50mph speeds... Not only makes a terrible racket, but tends to impressively ball-up into a mess when you go over a bump wrong. lol But, it IS an option, and if you're willing to make that compromise, it's certianly an option. The cyclone kits use the racheting front chainwheel setup, and it does work.
I want to get all the info out of this thread but it's 30 more pages to read! Can anyone give me an update on this project?
I would be in for a splined freewheeling sprocket if it is available now.
Paypal Thud $20. Send me freewheels. I've been broaching them for anyone and even paying return shipping to send them back at my own expense.
I'm actaully getting my father to take over the broaching work though, because he works at the shop where we have the broaching setup, and I tend to work 6 days a week or so and don't often want to spend my day off broaching. lol He doesn't like the idea of working for free as much as I do... lol
The member SloBuild made a fantastic donation after sending me 8 freewheels to broach, and it's going to cover the cost of the new broach (this one is rapidly loosing the corners of the teeth now... ), plus give some motivation to my dad to broach for me, because after I buy a new broach, I'm giving the residual to him.
Also... as dad's so often do... he made some subtle revisions to the process that improved it quite a lot. We've gone to press-fit's on them now, very snug, and this has reduced the potential for wobble on a large diameter sprocket.
I actually made a real-time video in HD showing every step of the broaching process, and the tools used to make it work. It's not an exciting video, but it's pretty educational.
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