Stinky with 80-100 and Nuvinci. NEXT BIKE Teaser pic inside!

Discussions related to motors other than hub motors.
This includes R/C motors, botttom bracket, roller and geared drives.
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E-racer   1 kW

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Stinky with 80-100 and Nuvinci. NEXT BIKE Teaser pic inside!

Post by E-racer » Jan 09 2012 8:46pm

The best the bike has done was 62 mph. Realistically it does 40 mph without completely destroying battery life. The 900 watt bulk charger works great and I am balancing using a RC charger. The $230 Turnigy battery pack has last 1,500 miles which is absolutely astonishing to me.



the bike
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NEXT BIKE! This is an early design concept teaser pic. The frame will be possible thanks to Cartesian CNC profiling and bending http://www.cartesiantube.com/
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The beginning
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pickup tubes
Image

pickup tube in swing arm tube with hardened shaft
Image

assembly
Image

Rear dropout section from the inside
Image

motor mounts and Torlon chain tensioner
Image

assembly
Image

fully detailed left dropout assembly 1/4" 7075 plate
Image

fully detailed right dropout assembly 1/4" 7075 plate
Image

view of the right side with frame
Image

2
Image

motor in its place
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2005 Kona Stinky

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Stock 80-100 from Leader Hobbies with typical loose windings

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Stock Windings Removed

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Rewound 80-100 12 turns delta, 14gauge wire, 88kv

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Rear View of Rewind this motors will be run with no skirt bearing.

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Nuvinci Developer Kit and Surly Large Marge Rim

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Wheel with Spokes! This is the first wheel I've ever laced, fun job! I recommend everyone do their own wheels.

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Wheel Tire Package: Maxxis Hookworm 2.5 26"

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Drive Train Layout from the bottom view.

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Going to make a swing arm from 5"x2" 0.125" wall aluminum.

I am approaching my design freeze within the next 2 weeks. Unfortunately I had to wait until the nuvinci dev kit got here to make measurements for the custom dropouts/NV servo mount.

The batteries will be 12s Turnigy li-po mounted in the swing arm tubes. Balancing/monitoring will be done by 2 resistor modded cell medics. The controller is a Kelly kbl48201 100/200amp I will be running Burtie's linear optical sensors.

There will be no pedals. In Georgia mopeds/scooters don't require pedals or registration :-D but are completely street legal any where except highways.
Last edited by E-racer on Sep 06 2012 12:09am, edited 14 times in total.
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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Byte   1 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by Byte » Jan 10 2012 6:09am

nice! I will follow this one :)

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GITech   100 W

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by GITech » Jan 10 2012 3:43pm

Wow, ha! How funny that I have been beginning to think along the same lines as your design.

I've also been staring at my bike for a year+ waiting to move forward with it.

Now that farfle is making custom 3" extended lowers for the rear suspension for my wally/kent Genesis I have been brainstorming with a similar drive idea.

(I know it's a wally bike, but it's the lowest cost frame that is close to a stinky (what I'd LOVE to have but is too costly for me), ...and by the time it is ready to ride the only stock parts left on it will pretty much be just the frame and rear suspension shock linkage. If I do a left hand drive from the rear lower, the stock peddle/chain system may stay... 'till it breaks)

I'll be watching! :shock:

Good luck,
Jay

Image
Ebike: Wallmart Genesis frame, unique Lovejoy 2-speed simplified/redundant drive mounted on custom aluminum swingarm conceptualized by me, machined by Thud. Brushless 80-100~100kv w/halls, 16s6p - 59.9v, 30Ah, 1.7+KWh, Fully Loaded Lyen 12 FET 3077 controller w/ Cycle-Analyst, full custom lighting.

Thanks to Justin at ebikes.ca for saving ES!

Ideas and projects by GITech are protected by: http://creativecommons.org/licenses/by-nc-nd/3.0/

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E-racer   1 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Jan 13 2012 1:37pm

Added the sprocket today. Parts are trickling in from the expanses of the interwebz. I hope to be riding in 2-3 weeks!
Image
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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drewjet   10 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by drewjet » Jan 13 2012 2:00pm

Looks like an intersting build, just be careful with the Nuvinci, as it is not happy at high power levels. I would definately keep it under 5KW. I toasted mine with 7500 watts.

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by SamTexas » Jan 13 2012 2:08pm

Subscribed.

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E-racer   1 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Jan 14 2012 1:37am

Thanks! @drewjet, I am a little concerned about the power level. My Kelly controller is a 100amp cont 200amp burst. People seem to think the Kellys are over rated on current. I think that 100amp x 50 volt = 5kw before controller losses, motor losses, and drive train losses. I am pretty confident this will keep me in the safe zone. Time will tell. I was brainstorming the other night and though of trying to use an IR temp sensor to monitor Nuvinci temp. This might be useful if I am pushing the duty cycle limits.
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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Kepler   1 GW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by Kepler » Jan 14 2012 6:18am

Looks like an excellent project. Also subscribed.

Great drawings too. What program are you using?
Current Rides

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E-racer   1 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Jan 14 2012 7:25pm

Thanks! I use Inventor 2012 (free for students). Ill put some real renderings up when I design freeze, probably Monday. These currently have no attention to lighting.
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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E-racer   1 kW

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Location: Marietta, Ga.

Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Jan 16 2012 2:16am

The rear end is all finally hashed out. Steel drop outs bolted to the aluminum extrusion with the NuVinci servo mount holes incorporated. I'm so close to being ready to build!
Image
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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Byte   1 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by Byte » Jan 16 2012 6:31am

Is that how the bike is going to look when it's done? If so, niceeee color combination :mrgreen:

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by kfong » Jan 16 2012 10:35am

Nice work, I would of used a thicker chain for the final output stage. The #25 stretches too much.

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GITech   100 W

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by GITech » Jan 16 2012 12:04pm

VERY nice E-racer! :shock:

Can't wait to see/read about the build!

Do you know what the current rating of your custom 12t 88kv motor will be?

Later,
Jay
Ebike: Wallmart Genesis frame, unique Lovejoy 2-speed simplified/redundant drive mounted on custom aluminum swingarm conceptualized by me, machined by Thud. Brushless 80-100~100kv w/halls, 16s6p - 59.9v, 30Ah, 1.7+KWh, Fully Loaded Lyen 12 FET 3077 controller w/ Cycle-Analyst, full custom lighting.

Thanks to Justin at ebikes.ca for saving ES!

Ideas and projects by GITech are protected by: http://creativecommons.org/licenses/by-nc-nd/3.0/

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E-racer   1 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Jan 16 2012 4:30pm

I use #25 on my Goped and yes it does stretch but its cheap and I just replace it once a year or so. The major advantages are its packaging size and off the shelf sprockets available for the Nuvinci flange.

The current rating is all based on what the controller can feed. My controller is 100amps X 48volt = 4800 watts. This figure is before losses.
Last edited by E-racer on Feb 05 2012 4:29am, edited 1 time in total.
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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farmkid4   10 W

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by farmkid4 » Jan 16 2012 5:07pm

Do you have any more pictures of the cad?

Looks great! cant wait to see more progress!

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E-racer   1 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Jan 16 2012 6:52pm

Image
Image
Image
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

User avatar
E-racer   1 kW

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Joined: Oct 22 2009 11:18pm
Location: Marietta, Ga.

Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Jan 17 2012 10:30pm

Did a fork rebuild today on my Marzocchi Drop Off triple. New Marzocchi seals, and new 7.5 weigh fork oil. Should be ready to ride! Image
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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E-racer   1 kW

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Location: Marietta, Ga.

Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Jan 23 2012 9:55pm

Exciting Day! First off, My rewound 80-100 runs with Burties optical board and the Kelly KBL controller! Secondly, all the aluminum is here!

Image

Here is the assembly taken apart a bit.
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The pickup point tubes will be made out of this 1.5" OD x 1.0" ID 0.25" 6061 tube.
Image

The Inserts will be made out of this 1.25" OD solid 6061 bar.
Image
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by edudins » Jan 25 2012 12:57pm

Hey! Where did you source the sprocket that goes on the 80100? I'm having some difficulties with the drive train design on mine. I was planing to make a FWD ebike, with a 80100 going to a hub, and I need to keep in mind that one of those has to be a freewheeling sprocket, otherwise the rolling resistance would be huge, and I want to pedal also when the battery is flat :)

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E-racer   1 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Jan 25 2012 4:22pm

Sprockets are readily available from http://www.mcmaster.com or http://www.electricscooterparts.com/ You'll have to take your freewheel advice from somone else. I don't mess with them (no human pedals) and the Nuvinci hub freewheels.

I NEED DROPOUT ADVICE!
I am seriously considering changing my dropout material from 1/4" thick 1018 steel to 1/4" 7075 aluminum. Everything else on this swing arm is aluminum. I am pretty confident the 7075 would hold up. The main issue I am seeing is that the supplied torque arms only have 1/8" engagement into the dropout. Any input? What kind of torque does the axle on this thing see?
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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Kepler   1 GW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by Kepler » Jan 25 2012 4:56pm

I would think that the Aluminium dropouts will be fine. Most of the torque is going to wheel not the dropouts. You only need super beefy dropouts with with high powered hub motors that transmit all their torque to the dropouts.
Current Rides

Lightest true ebike on the planet: ON ROAD https://endless-sphere.com/forums/viewt ... =6&t=74269
eBoost on facebook: http://www.facebook.com/pages/Eboost/200306283342024/
75 Volt 6 kW FUTR Beta 29'er: OFF ROAD

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by biohazardman » Feb 03 2012 2:09pm

I thought that the Nu-Vinci axles were posed to be mounted on horizontal dropouts. Are you mounting them other than that?
Build it like your life depends on it. Cuz it does.
Golden Motor Schwinn first build http://goldenmotor.com/SMF/index.php?topic=279.0
Giant BMC build http://endless-sphere.com/forums/viewto ... &start=390
Short ride vids http://endless-sphere.com/forums/viewto ... 60#p321703

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E-racer   1 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Feb 04 2012 6:15am

biohazardman wrote:I thought that the Nu-Vinci axles were posed to be mounted on horizontal dropouts. Are you mounting them other than that?
"The preferred mounting includes horizontal dropouts to allow for chain/belt tension adjustment,
though vertical dropouts can be used with a chain/belt tensioner (not included)."
http://www.fallbrooktech.com/docs/DevKit_Manual.pdf


O! and an update on the bike! I'm almost done with the machining! spent 14hrs in the machine shop at my school today. We got a completely new building and a really great new lathe since I last worked in that shop. All is going well. I will post pics after I do my final cuts.
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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biohazardman   100 kW

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Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by biohazardman » Feb 04 2012 11:15am

Thanks, missed that little bit so guess I will not waste so much time looking for horizontal dropouts from now on.
Build it like your life depends on it. Cuz it does.
Golden Motor Schwinn first build http://goldenmotor.com/SMF/index.php?topic=279.0
Giant BMC build http://endless-sphere.com/forums/viewto ... &start=390
Short ride vids http://endless-sphere.com/forums/viewto ... 60#p321703

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E-racer   1 kW

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Location: Marietta, Ga.

Re: The build begins. 80-100, Nuvnci, Turnigy Li-po.

Post by E-racer » Feb 05 2012 4:23am

pickup tubes
Image

pickup tube in swing arm tube with hardened shaft
Image

assembly
Image

Rear dropout section from the inside
Image

motor mounts and Torlon chain tensioner
Image

assembly
Image

fully detailed left dropout assembly 1/4" 7075 plate
Image

fully detailed right dropout assembly 1/4" 7075 plate
Image

view of the right side with frame
Image

2
Image

motor in its place
Image
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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