dnmun wrote:Rebuild It Perfect
Really, it's preferred.
by taking the cracked dropout to real welder and see if he can repair it for you. i bet most welders could make it twice as strong as original for half the money it cost new. that was a nice rig. you need a front suspension fork anyway. this is a good excuse. you went through 3 batteries already?
The 1" steerer tube limits ones choice for boinger forks. There's not much weight on the front except under braking. The Big Apples are enough suspension on the streets I ride.
Repairing a forged dropout doesn't inspire much confidence.
I'm suspecting the dropout may be a weak spot in the Free-Radical design. Interbike 2012 they showed a "Leaper" that uses a curved rectangular tube in place of two tubes. The dropout is welded to the underside of that eliminating the dinky tang of the dropout. I'm also suspecting the X5 has been trying to twist that off all along. (no added torque arms, just tight nuts and no regen) Adding the motor weight and it seems that thanks to Xtracycle's quality it's done 8 years faultless service. Without having added the motor, or Riding the Spine, it would probably still be intact. Hell, torque arms may even have prevented it.
I don't ride off curbs and am generally pretty easy on my equipment.
First controller lasted ~650 km. Justin replaced it with the only controller in his store, A hand built sample 12 FET Xlyte. It's still working fine. The motor's hall sensor connections have probably corroded off inside the hub. I bought a sensorless one in March.
The batteries were some of Justin's first ventures into Chinese battery suppliers. First packs were 24V 18 Ah NiMh. I returned them for repair the third time and told Justin I never wanted to see those things again. It was around the time I was building EBII so I'd already bought a 48V LiFePo4 triangle pack for it. Then bought a second one so I could run them on the X5. Justin built me parallel harness for them. When those batteries also began proving bothersome Justin started handling the E-Zee LiMn packs exclusively. He gave me a pair of the slightly under performing 8 Ah packs when the LiFePo4 packs acted up for their last time. These 48V 8Ah LiMn Samsung 3C packs have 508 cycles, 3031 total Ah. They're still good for about 11Ah compared to the ~13Ah when they were new. One of the LiFePo4 packs is still working. All totaled, for 63 months of daily riding, $2400 on batteries for two bikes. Any downtime for battery repairs Justin always provided me with a loaner pack of some sort.
If it weren't for ebikes.ca great service I'd have probably packed it all in out of desperation and frustration.