Mid Drive Steel Frame Bike 10kw Alternator Sunwin Controller

Sauger-Junky

10 mW
Joined
Oct 15, 2017
Messages
29
Hi,
i will show you our build we do the last months .
The Motor is a old Bosch Car Alternator it has 4500 rpm at 75Volt we do it like Sur-Ron 14 to 35 teeth to the pivot point and from there 14 to 51 teeth.
As Controller we try a 1500w Sun Fire some people run it till 7500w we will see...
The Frame is made by steel S235JR most in 40x20mm and WIG welded.
We hope we can do the first testdrive in the next weeks.

View attachment 3DSC_0936m.JPGDSC_0937m.JPGDSC_0938m.JPG
 
Today it gets a big step with the gear and the rear axle
 

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concentric is a god idea but it is faster and easyer for the first build with slide drop out because the bracke can slide with the axle and we can use 19" up to 26"
concentric and bracke position ist tricky
 

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Sub’d nice looking build! Nice to see someone tackling a jack shaft! Lets see if it puts the power to the ground when its done!
 
Now we install the Motor and wheels
 

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Any idea what the weight will be at the end?
I like this style of frame..the curved sections remind me of 'Pie Cuts' when welding up exhausts!
 
We did some test runs and now we know the motor lose at 50 amp the magnetic field.
We cnc mill a new rotor. the rotor has a 103mm dimeter and it is 40mm wide so we think it is able to run till 12 kw :eek:
also we order a 96v sunwin controller that we can run 24s 2p 8ah
 

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Now the parts for the alternator motor are complete.
its a 36n 12p so we make 2 magnets fore eatch pole that we get 24 magnets
 

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very nice fab skills! is that MIG welding?

btw i'm just a bit concerned about the strength of the swingarm since you cut holes in it (red arrow). this weakens the rectangular tube. maybe you could weld a circular "cap" over the hole to strengthen it

SQ13YyM.jpg
 
thanks
it is TIG welding.

yes we have a eye on it but it ist crasy stable.

after the welding we had to bend it 1mm back ... impossible

from that are the heat traces i bend it just with heat
 
That seat is 8 inches from the handlebar, just in case you wanna sit close to the action? :x
 
what a great job it is

have you tested the new alternator
it's possible to make a video

is it possible to remake a rotor and sell it?
 
Yes the seat is from a KTM sx and there it hast nearly the same position
in full acceleration uphill you need to slide more to the front :wink:
 
i hope we can test the rotor this weekend
we make a video if it runs good

the rotor ist cnc mill on my machine so yes if it works good i can do more
 
today we install the magnets
it very hard because they where very strong
 

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190120021435110821.jpg



it's not a little thin at the level of the red arrows? his risk of breaking

what glue did you use?
 
The motor in now back in place.
with the new magnets the top speed go down from 37kmh to 30 kmh but now the magnetic field is stable.
we change the wiring now from star to triangle so the speed increase x1,7 to 51kmh
and after that we cage the battery from 18s to 24s to get 68kmh top speed

https://youtu.be/dENpXyG3_0o
 
Dang that's a nice build,.. you guys are awesome!!! :bigthumb:

Hope your going to do a short video when it's done! :)
 
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