NAHBS 2014 mid-drive build

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PaulD
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NAHBS 2014 mid-drive build

Post by PaulD » Mar 25, 2014 12:17 am

Hey ES,
I thought I'd post some build pics of the ebike that I took to the North American Handmade Bike Show in Charlotte, NC last week. I had the opportunity to work with a super talented industrial designer and go from concept to prototype over a 6 month period.
As many of you know, NAHBS is typically not the kind of show where ebikes are welcomed, but fortunately Gates wanted to display a few ebikes utilizing their belt drive, which opened the door to allow me to bring an ebike. Paul Brodie had brought an ebike to NAHBS in 2013, but the organizers were hesitant to allow them this year. Good thing a big company like Gates believes in the electric revolution!
Anyways, other than gates, I had the only ebike, so I got a lot of attention. I had the pleasure of meeting Snath (Larry) who traveled from Atlanta. It was great to meet an ES member there, and Larry showed me some of the cool battery stuff he is working on and some of his builds.
Anyways, here are some pics of the build process. Things were rushed (understatement) leading up to the show, so it's amazing that everything came together in time!
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Re: NAHBS 2014 mid-drive build

Post by Miles » Mar 25, 2014 2:06 am

Hi Paul,

Nice work!

What motor did you use?

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Re: NAHBS 2014 mid-drive build

Post by Miles » Mar 25, 2014 2:16 am


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Re: NAHBS 2014 mid-drive build

Post by PaulD » Mar 25, 2014 9:34 am

Hi Miles,
Thanks for posting those pics. I have a ridiculous look on my face in the Gizmag photo! I thought that I was out of the picture!
The motor is a transmagnetics 4" unit. The total gear reduction to the crank is 30:1.
-Paul

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Re: NAHBS 2014 mid-drive build

Post by snath » Mar 25, 2014 10:24 am

Paul's craftsmanship and attention to detail was equal to any that I saw at the show. Not to mention, of course, that his was a way cool ebike!

It was really neat to meet up with a noted ESer.

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Re: NAHBS 2014 mid-drive build

Post by onlineaddy » Mar 25, 2014 10:45 am

Beautiful work of art! I'll have to say, though, that the best picture of the bunch is the one with the dog. :wink:

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Re: NAHBS 2014 mid-drive build

Post by spinningmagnets » Mar 25, 2014 10:55 am

Mind if I write an article about this bike? Thanks for posting this, either way.

If it's any consideration...I have it on good authority that Vladimir Putin does not want you to allow me to write about this, and I think you should stand up to assert your rights as an independent E-biker, if only as a symbol of hope and freedom for E-bikers everywhere.

edit: as much as I am hesitant to critique what is clearly a work of art and the organic display of an untamable genius...it could use a billet coffee cup holder and a suspension seat-post?
Last edited by spinningmagnets on Mar 25, 2014 6:25 pm, edited 1 time in total.

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Re: NAHBS 2014 mid-drive build

Post by Avitt » Mar 25, 2014 11:31 am

onlineaddy wrote:Beautiful work of art! I'll have to say, though, that the best picture of the bunch is the one with the dog. :wink:
Agree. That photo is striking!

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Re: NAHBS 2014 mid-drive build

Post by K-ray » Mar 25, 2014 1:11 pm

Gorgeous creation Paul :shock:
Curious about it's final weight?
Kudos!

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Re: NAHBS 2014 mid-drive build

Post by PaulD » Mar 25, 2014 7:44 pm

Thanks for the comments, all.
Ron, no problem on writing an article on the bike, I'd appreciate it! Let me know if you have any questions.
K-Ray, total weigh is about 38lbs. The goal was to keep the weight down and as close to the bottom bracket as possible. This will hopefully make it feel as agile and bike-like as possible.

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Re: NAHBS 2014 mid-drive build

Post by liveforphysics » Mar 26, 2014 1:58 am

Paul! Raising the bar my friend! Outstanding!

You are an artist! I'm blown away!

Next race we are gonna do, you gotta let me ride it!
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Re: NAHBS 2014 mid-drive build

Post by spinningmagnets » Mar 26, 2014 9:02 am

Looks like the bike was commissioned by Green Pea Bikes (hence the color chosen). Found another pic to add to the list.
PaulD6.jpg
PaulD6.jpg (80.94 KiB) Viewed 33 times

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Re: NAHBS 2014 mid-drive build

Post by grindz145 » Mar 26, 2014 9:38 am

Pure Artwork. We all need to aspire to this attention to detail!

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Re: NAHBS 2014 mid-drive build

Post by spinningmagnets » Mar 26, 2014 10:30 am

Here's the photo gallery from the Green Pea Bikes Facebook page:

https://www.facebook.com/greenpeabikes/photos_stream

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Re: NAHBS 2014 mid-drive build

Post by PaulD » Mar 26, 2014 11:34 am

Thanks guys. The true artist is the industrial designer, Michael Hritz. You can see some of his other work here: https://www.facebook.com/michaelhritzart
I just took his art and made it into an ebike.
Oh and that is my girlfriends dog, Molly. She's a sweet dog, and is far more photogenic than me.

Luke, at 750 Watts, it's no race bike, but you'll definitely have to take it for a spin when. I see ya next!

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Re: NAHBS 2014 mid-drive build

Post by Warren » Mar 26, 2014 4:06 pm

Paul,

An absolutely gorgeous bike. I saw the show when it was in Richmond, Virginia in 2010. Handbuilt craftmanship to make you cry. Glad to see more e-assist entries.

Is 38 pounds with the battery pack installed? If so, how many Wh is the pack?

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Re: NAHBS 2014 mid-drive build

Post by spinningmagnets » Mar 26, 2014 7:06 pm

Here it is, 90% done. I will add more details and possibly some corrections as information comes in...

http://www.electricbike.com/nahbs-2014- ... mid-drive/

Paul just checked in, more details will be added to the article tomorrow morning.
Last edited by spinningmagnets on Mar 26, 2014 8:41 pm, edited 1 time in total.

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Re: NAHBS 2014 mid-drive build

Post by PaulD » Mar 26, 2014 8:05 pm

Warren wrote:Paul,

An absolutely gorgeous bike. I saw the show when it was in Richmond, Virginia in 2010. Handbuilt craftmanship to make you cry. Glad to see more e-assist entries.

Is 38 pounds with the battery pack installed? If so, how many Wh is the pack?
Thanks Warren. There were some amazing bikes at the show. The craftsmanship and detail is crazy on some show bikes. I shudder at the amount of time put into finish work and small details.
The 38lbs is with a 470wh pack. I am working on some changes that may result in a slightly heavier pack, but I think some weight can be taken out of the frame and drive system...

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Re: NAHBS 2014 mid-drive build

Post by liveforphysics » Mar 26, 2014 8:09 pm

Wow!! That's such a light bike for having a very useful amount of battery on board! Fantastic job as usual my friend!

I love the picture of your Dog with the brazed frame, something is very artistic about it. You and your lady and dog are always welcome to visit again anytime you like. :-)
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Re: NAHBS 2014 mid-drive build

Post by PaulD » Mar 27, 2014 12:23 am

liveforphysics wrote:Wow!! That's such a light bike for having a very useful amount of battery on board! Fantastic job as usual my friend!

I love the picture of your Dog with the brazed frame, something is very artistic about it. You and your lady and dog are always welcome to visit again anytime you like. :-)
Thanks buddy. Very few ebikes have the insane level of weight saving efforts found on modern road bikes. I think there is a lot of room for improvement on high end ebikes. And, you and your wife are always welcome here if happen to be passing through Ashland.

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Re: NAHBS 2014 mid-drive build

Post by Warren » Mar 27, 2014 10:24 am

Paul,

"The 38lbs is with a 470wh pack.

Yeah. I realized, after I wrote to you, that I could figure it pretty close from your photo of the naked pack...10s4p?...that it was around that size.

"Very few ebikes have the insane level of weight saving efforts found on modern road bikes."

For a steel bike, with a reasonable amount of battery, you are doing great.

There is this, but the drive and battery is tiny. Drives like this can work, but only for an avid cyclist.

http://www.electricbike.com/lightest-bike/

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Re: NAHBS 2014 mid-drive build

Post by spinningmagnets » Mar 27, 2014 10:46 am

This transmagnetics 4-inch diameter motor is VERY similar to the GNG motor, but smaller. It has a low pole-count, but...it also has the desirable thin 0.35mm laminations. Between the two, this motor should be able to be run very happily in the 72V range (if you want).

By the way, I added the details provided by Paul, so the article is 99% done now. After staring at the frame for a while, I noticed a few other things about it, this is a more sophisticated design than what I had at first thought. Paul states he was inspired by the Green Pea Bikes concept design, put together by Michael Hritz.

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Re: NAHBS 2014 mid-drive build

Post by Warren » Mar 27, 2014 11:17 am

I am confused...no news there...how do you wire up 40 cells to get a "48" volt system?

https://scontent-b-sea.xx.fbcdn.net/hph ... 3330_n.jpg

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Re: NAHBS 2014 mid-drive build

Post by Drum » Mar 27, 2014 11:45 am

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.
Many bronzes are significantly stronger than mild steel.
I used to modify motorcycle frames quite a lot, and always brazed them rather than welded. Brazing has several advantages over any form of fusion welding:
-The parent metal is not melted during the operation, so does not tend to become brittle along the edge of the weld;
-The bronze (when brazed by a skilled operator) tapers nicely from its maximum thickness in the middle of the joint down to the surface of the parent metal. This feeds the stress from the joint smoothly into the parent metal. Some welds change cross section rapidly at their edge, producing a "stress-raising" sudden change in area.
-Both of these factors mean that a brazed joint can be significantly less affected by fatigue than a weld.
And, as you say, can look nice as well

For these reasons, the tubular chassis of the Arial Atom sports car is brazed, not welded. They had to go round the old folk's homes to find retired craftsmen who were skilled in brazing, because it is pretty much a "lost art"! The retirees taught a new generation the methods.. and a few frame builders are keeping it alive too.
Regards,
Dave

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Re: NAHBS 2014 mid-drive build

Post by PaulD » Mar 27, 2014 12:22 pm

Warren wrote:I am confused...no news there...how do you wire up 40 cells to get a "48" volt system?

https://scontent-b-sea.xx.fbcdn.net/hph ... 3330_n.jpg
Good eye, Warren. That is the first prototype pack when I was running at 36V. I was so rushed I didn't take pictures of the current pack.

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