Wow...very nice work CD. I have to admire your patience. There are few things in life more satisfying than bringing an old clunker back to life. Hat's off to you.
Thanks for the kind words.
My 'thing' with this bike is to only use the cheapest recycled parts I can unless absolutely necessary.
So far, the original motor is working well at 3 x it's original power with oil cooling, so no need to upgrade that.
My controller is an 18Fet Infineon I used to run on my Stealth Fighter before I replaced it with an Adaptto. The infineon has an intermittent hall sensor issue which cannot be fixed, but it doesn't seem to happen in colder weather or at low power anywhere near as often, so powering this bikes little geared hub is a perfect job for it.
Similarly, the throttle and power switches came over from my Stealth Fighter with the Infineon controller.
The batteries have seen a bunch of use elsewhere also. Initially they were in my Stealth Fighter:
Then, once they started hating the 5-6KW abuse they saw on the Fighter at around 150 cycles, most of them moved over to my Recumbent and managed another 200 cycles at 1-2KW:
And now with over 300 cycles they are good enough for use on this old clunker which draws a max of 750W:
Hopefully they last at least another 200 cycles before I'm forced to ditch them for good.
Apart from that, the speedo was moved over from another regular bike which I barely use. The grips were spares I bought ages ago, but never used, and the pedals were the originals that came on my recumbent.
The only new parts I've bought for the bike were the Bottom bracket axle/cups to repair those issues, and the crank set that came with a larger chain ring to allow pedalling at higher speeds.
So all up, this bike is doing pretty well for such minimal investment. I'm pretty happy with it.
The only thing that's not working so well at the moment is the rear drum brake. If I tighten it up so it works well when the lever is pulled, it starts rubbing serverly. At the moment it's only tensioned very loosely so that it doesn't rub, but the braking force is pathetic and pulling the lever all the way in barely slows me.
Part of the problem seems to be aligning it. If the bolt holding the cover arm on is not spaced out perfectly from the rear chain stay, it starts rubbing badly. I lost the original bolt, so I'm using a smaller diameter, longer allen head bolt currently with a bunch of nuts and washers to space it out.
Any suggestions for improving the rear drum brake performance?