Project: Home made velomobile design with crank or mid motor

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tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jun 21 2015 10:59am

Glued to the rear wheel:
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tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jun 28 2015 1:30pm

Painting detailed surfaces is boring.

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--freeride--   100 W

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Re: Project: Home made velomobile design with crank or mid m

Post by --freeride-- » Jun 29 2015 3:15am

Very nice work!

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1JohnFoster   1 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by 1JohnFoster » Jun 29 2015 10:12am

I filled a large rough section of plywood with plastic body filler. Got really smooth, but it showed up as a big ugly blotch under the wood stain. Then I spent waaaay more time sanding it back off than I had in putting it on. Biggest mistake of my build.

People always praise the "workmanship" of my build - but its really just the big impression made by the wood stain and glossy varnish. My workmanship is actually pretty rough. What worked out really well was to hide all the botchy filled parts (the corners) with opaque paint, and "feature" the smooth flat sections in stain. :twisted: If I'd painted it all opaque paint it would look like an old cupboard on wheels. People compare wheeled vehicles to cars; they expect perfectly smooth hard glossy surfaces with very complex curves. Varnish makes the comparison vanish.

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r3volved   100 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by r3volved » Jun 29 2015 11:09am

Well...I praise your workmanship because if I built that, it'd be a 30mph splinter factory.

Wood isn't even very hard to work with...I just could not conceivably create something as gorgeous as that (at this point in my life)

tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 06 2015 5:18pm

I have rounded off the edges with a plunge router, and primed the outside.


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Wheazel   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by Wheazel » Jul 06 2015 5:39pm

Exciting stuff! How many labor hours do you estimate this project requires?

tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 06 2015 6:24pm

I have no idea. Most of the time has probably been spent designing it.

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dequinox   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by dequinox » Jul 07 2015 12:15am

Do you have a rough weight of the structure w/o the bike components so far?
On a dusty pew in a vestibule sits the Devil playing pocket pool, he's waiting for the next poor fool who forgot that it was Sunday

STABLE:
HI-V (Retired); Sun Cruiser w/ Hill Topper Kit; Giant Simple Cruiser w/ Amazon 1000W Front Hub.
Parts donated by Rassy and Greenerwheels have made many of my builds possible, THANK YOU!!!

tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 07 2015 9:23am

The body weighed 20 kg before I started painting. Probably a kg heavier now. The completed weight will probably be 60 kg+ with the motor and batteries.

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dequinox   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by dequinox » Jul 07 2015 6:46pm

That's not terribly heavy for a velo, I think that's quite reasonable.
On a dusty pew in a vestibule sits the Devil playing pocket pool, he's waiting for the next poor fool who forgot that it was Sunday

STABLE:
HI-V (Retired); Sun Cruiser w/ Hill Topper Kit; Giant Simple Cruiser w/ Amazon 1000W Front Hub.
Parts donated by Rassy and Greenerwheels have made many of my builds possible, THANK YOU!!!

tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 08 2015 7:41am

I think it'll be ok. I have ridden my surly Ebike with a total weight of 50 kg once with a flat battery. Very hard to climb the long hill home, but the 46/25 drivetrain idn't exactly help either.

What I'm really curious about is the aerodynamic aspect. I hope for a big positive surprise. :) I'll use my power meter rear wheel to see how it compares to my road bike.

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dequinox   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by dequinox » Jul 08 2015 3:28pm

Aero is tricky. Your side profile is excellent, but I think the simple flat-sided design is going to lag behind a fully complex-contour design in performance. I do think you'll see some significant gains in efficiency over a bare trike or bicycle, especially over 10 or 15 mph.

Here are some simple references that give you a rough idea of how 2D shapes affect the amount of drag... the shape coefficients plug into the drag equation below for simple 2D calculations. "A" is the frontal area of your velo.

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tahustvedt wrote:I think it'll be ok. I have ridden my surly Ebike with a total weight of 50 kg once with a flat battery. Very hard to climb the long hill home, but the 46/25 drivetrain idn't exactly help either.

What I'm really curious about is the aerodynamic aspect. I hope for a big positive surprise. :) I'll use my power meter rear wheel to see how it compares to my road bike.
On a dusty pew in a vestibule sits the Devil playing pocket pool, he's waiting for the next poor fool who forgot that it was Sunday

STABLE:
HI-V (Retired); Sun Cruiser w/ Hill Topper Kit; Giant Simple Cruiser w/ Amazon 1000W Front Hub.
Parts donated by Rassy and Greenerwheels have made many of my builds possible, THANK YOU!!!

tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 15 2015 3:16pm

Some progress. I'm taking it easy at the moment. I'm focusing on the bottom so that I don't have to flip it around any more. The paint has to dry between sessions anyway so I can't rush it, though I could make some other parts in my router if I wasn't so lazy.

I sanded it today and primed the exposed wood from sanding.
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tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 16 2015 5:12pm

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tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 18 2015 5:15pm

Wet sanding to eliminate orange peel. The right side has been sanded.
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Here it is after sanding and spraying on a new coat.
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Wheazel   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by Wheazel » Jul 18 2015 8:29pm

Looking good! All going as planned?

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Re: Project: Home made velomobile design with crank or mid m

Post by giantNRS1 » Jul 19 2015 12:59am

Have you seen this:

http://organictransit.com
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tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 19 2015 8:46am

Wheazel wrote:Looking good! All going as planned?
Pretty much, except I made a big mistake when I made the sheet for the nose. I only had plywood with longitudinal surface plies and figured I had to use it to save money. I should have bought a new sheet because it's not smooth around the bend. I knew it was a bad move when I did it, so it was sheer stupidity. I will try to fix it by installing internal supports. I also redesigned the internal frame to reduce weight and incorporated it into the front supports, so it seems to work out in the end. It also is turning out a lot heavier than I had hoped, but I have to remind myself that it's not a problem because I will have nearly 800 W extra power to help me in hills.
giantNRS1 wrote:Have you seen this:

http://organictransit.com
Yeah, the Elf was one of the velos that made me realize that I can actually replace my car. I think it's too big, and I couldn't find any velos I liked that fit my bill, so I had to make my own. :) I recently learned about this one, which could have been an alternative for me: http://arcusvelomobile.com/

tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 19 2015 12:01pm

Plasti Dip in the wheel well
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etard   1 MW

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Re: Project: Home made velomobile design with crank or mid m

Post by etard » Jul 19 2015 12:39pm

*subscribed

Awesome build, hats off to you man!

I hope we never see any crash testing on this design, but it looks very strong!

I've been thinking about using an unfinished airplane fuselage as a velomobile, your body reminds me of wood airplane construction. Loving the solid milled aluminum too. Who needs a welder? Not THIS guy!

8)
Four wheels moves the body, Two wheels moves the soul
Thanks to Justin @ http://www.ebike.ca He brings the soul to ES

tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 19 2015 4:11pm

Here are the support frames for the front. I should have made those folding slits all the way down, which would probably have worked.
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The rear hatch fits well. Slightly tight fit halfway down the length, but it's almost perfect.
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Wheazel   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by Wheazel » Jul 19 2015 6:05pm

thats a big battery compartment :)

tahustvedt   10 kW

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Re: Project: Home made velomobile design with crank or mid m

Post by tahustvedt » Jul 19 2015 6:25pm

That's just for groceries. :) The batteries will be in the nose and/or under the floor to keep the CG in the right place.

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Re: Project: Home made velomobile design with crank or mid m

Post by ErnestoA » Jul 20 2015 12:08am

I LOVE this build! :D

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