Snow Beast Refurb

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DrkAngel
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Snow Beast Refurb

Post by DrkAngel » Dec 15, 2017 9:45 am

.
...
2008 eZip Mountain Trailz ... purchased new in 2008 - $395
Image
24V 450w cruised at ~16mph but was afflicted with 16lb of 10Ah Lead Acid batteries.
Ran daily and converted to 36V. When controller died installed 36V 25Ah eZip scooter controller and 36V led throttle.
Experimented with recycled laptop cells and built my 1st 36V Lithium batteries.

Later in 2008, I got a bargain on a 2008 eZip Trailz (smooth road tires and "stealth" black).
Set aside the Mountain Trailz`till Winter

Suffered through the Winter of 2008-09 on Mountain tread tires ...
... vowed to find a better way ...
2009 purchased cheap Innova studded tire, worked good but steel studs wore right off on bare roads.
Decided to build my own studded tires, with replaceable studs. After a bit of hunting I finally decided on building my own Winter tires using 3/8 & 1/2" sheet metal screws. - Homemade Studded Tires
Winter of 2009-10 was born ...
the Snow Beast
Dedicated Winter vehicle with:
675 watt output motor, geared for max output near 17mph
studded tires
comfy-weatherproof seat set low to ski with feet
flashing front and rear lights
Last edited by DrkAngel on Dec 15, 2017 4:36 pm, edited 1 time in total.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

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Re: Snow Beast Refurb

Post by DrkAngel » Dec 15, 2017 10:07 am

Winter of 2017-18 ...
10th Winter for the Snow Beast
Usually I take to the car wash and wash and hotwax the Snow Beast for Summer storage.
But these past couple years, either I forgot to hit the hotwax button ... or carwash owner ran out of wax or, as many suspect, there is no hot wax.
Anyhow, Snow Beast is turning into rust heap.
Freed up all cables, brakes, chain, derailleur etc
Trued and checked wheels and brakes
Strapped on 33.3V 43.2Ah six-pack battery and took off ... oops!

Throttle lit up but no fire from the motor?
Seems T-plug I added for motor quick disconnect got corroded. Couldn't get it apart till using dual pliers method, and broke 1 wire in the process. Just cleaned T-plug and pushed wire back into heatshrink and was able to get motor going for test.
Chain skips! Stretched from 10 Winters of use and rust!?

Starting to tally up repair list ...
T-plug replaced with, more weather resistant XT60
New chain
Oops ... rear wheel feels-sounds "gritty" ... bigtime!

Major project!
Wheel has 10 year, Winter hardened freewheel with no removal notches!
Last edited by DrkAngel on Dec 18, 2017 7:23 am, edited 2 times in total.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

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Re: Snow Beast Refurb

Post by DrkAngel » Dec 15, 2017 10:25 am

New repair list:
T-plug replaced with, more weather resistant XT60
New chain (ordered "stainless" chain. so might do later)
All new cables
New-used derailleur - does not lift chain for step to larger sprocket
Rust removal - removable parts soaked in vinegar for a week clean perfectly!

Wheel rebuild - project unto itself
Only eZip wheel to never have suffered broken spokes!
So, need to cut off oem 20T motor side freewheel
Disassemble, clean, inspect, repair-rebuild axle-hub
Inspect, test spokes-wheel and true up.
Install 22T motor side freewheel for more torque at lower speed

33.3V battery is too large-awkward and 33.3V hits controllers 31V LVC too soon, especially when battery cold.
BigBat1.jpg
BigBat1.jpg (154.39 KiB) Viewed 726 times
Will drop 3x 36V 4.4Ah hoverboard packs into eZip battery case for 36V 13.2Ah battery. (These Samsung cells have great output and cold weather performance!)
IMG_8536.jpg
IMG_8536.jpg (146.3 KiB) Viewed 726 times
Too cold to ride, single digits this morning, so might make good progress this weekend?
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

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DrkAngel
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Re: Snow Beast Refurb

Post by DrkAngel » Dec 15, 2017 4:33 pm

.
......
Not "left out in the weather!"
"Run in the weather"... for 10 years!

Great on fresh snow
Good on ice
Good on snow (to 1"+) over ice
Almost tolerable with accursed brownish salt-snow crud
.
SBR1.jpg
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SBR3.jpg
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SBR4.jpg
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SBR5.jpg
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.
But not just your normal weather!
We're talking Upstate New York with liberal salt on the streets!
Salt eats up steel and aluminum.

Kickstand and seat tube clamp were chrome plated steel!
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

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DrkAngel
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Re: Snow Beast Refurb

Post by DrkAngel » Jan 03, 2018 3:48 pm

Got lazy ...
Multiple of my old eBikes have AC plug connection to batteries,

Image
rather than converting everything, I just made a little adapter for my newer 37v packs.

AC - XT60.jpg
AC - XT60.jpg (50.7 KiB) Viewed 581 times
Yes, Snow Beast refurb going slow ... SS pedal chain is in the States (from China) now so might be able to accomplish during this nasty cold snap ... lasting into next week.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

markz
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Re: Snow Beast Refurb

Post by markz » Jan 03, 2018 8:17 pm

-45C (-40F) a few days ago now to 0C (33F)
ebiking with only my speedo on today 8)

Them rusty bits give the bike character and age, plus its a built in anti-theft device.

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Re: Snow Beast Refurb

Post by DrkAngel » Jan 04, 2018 6:25 pm

Out of necessity ... finally progressed on fix-up.
Motor side freewheel failed!

Pulled wheel and motor,
removed chain (2 inches longer than same tooth count replacement),
Replaced failing T-Plugs with XT60's,

20T.jpg
20T.jpg (127.46 KiB) Viewed 483 times
Built new wheel motor combo
Used spare wheel, will dismantle and rebuild SB wheel later.
Replaced 20T oem motor freewheel with 22T, for more torque,
built longer motor chain 9T >> 22T needs 30T (15 links)
heated chain (hair dryer) and coated with Finish Line "Wet" chain lube, worked in till chain "flowed" smoothly
replaced 14-28T oem 7spd with 14-34T, for more, pedal, torque
Reassembled with new shiny nuts n such

22T.jpg
22T.jpg (133.66 KiB) Viewed 483 times
Runs nice ... but still need to replace derailleur, chain and cables, for full function.
Last edited by DrkAngel on Jan 05, 2018 3:41 pm, edited 2 times in total.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

markz
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Re: Snow Beast Refurb

Post by markz » Jan 04, 2018 8:28 pm

You plan to pedal.
Whats that? :twisted:

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DrkAngel
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Re: Snow Beast Refurb

Post by DrkAngel » Jan 05, 2018 6:15 am

2007-08-09 eZip motor freewheel removal is problematic.

Image
Freewheel has no removal tans or notches.
There are 2 pitiful detents, but are in a pressed fit sidewall

Image
When new, before motor is run, it has been possible to remove using them, but after motoring on, or weathered removal requires more drastic-creative measures!
Various methods involve:
Cutting sprocket ring off then using pipe wrench;
Placing freewheel in strong vise, crushing sprocket, turning wheel
Heating, torch, can help

The 22T Ditca replacement freewheel, similarly has only the small detents.
I am hoping to be able to remove ... coated threads with FelPro C5-A anti-seize lubricant.
A grease-copper-graphite lubricant. I also use to enhance-protect electrical connections!

Motor side requires a LHS (Left Hand Screw) freewheel available, almost exclusively, from ACS who produces 16-18-20T models.
Ditca supplies the lesser quality 22T I am using on this eBike. I am looking to provide the most torque and 20mph "legal" from 36V on the 24V 450w eZip. @ 36V 450w motor is capable of ~675 watt output. With the volting up and gearing down, performance is greatly enhanced!!!
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
DrkAngel
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Re: Snow Beast Refurb

Post by DrkAngel » Jan 05, 2018 6:52 am

DrkAngel wrote:
Jan 05, 2018 6:15 am
Ditca supplies the lesser quality 22T I am using on this eBike. I am looking to provide the most torque and 20mph "legal" from 36V on the 24V 450w eZip. @ 36V 450w motor is capable of ~675 watt output. With the volting up and gearing down, performance is greatly enhanced!!!
My favorite ...
MY1018z 24V 450w motor @ 25.9V and geared 20 >> 16T for 20mph cruising
vs
MY1018z 24V 450w motor @ 36V and geared 20 >> 22T for 20mph slogging through slush and snow
(20mph estimated via knobby studded tires, through nasty road, in the cold)

Unite 20mph.jpg
Unite 20mph.jpg (216.34 KiB) Viewed 442 times
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
DrkAngel
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Location: Upstate-Western-Southern Tier NY. USA

Re: Snow Beast Refurb

Post by DrkAngel » Jan 06, 2018 4:53 am

Right on cue, "Stainless Steel" pedal chain arrived from China ... yes, sticks to magnet ... oh well, will have to monitor for any sign of rust.
Chain no longer "skips". Did arrive nicely lubricated!

Image

Ordered up better quality chain for the motor side

Image

Heavy construction and nickel plating should enhance extend life and reliability.
Bonus! 112L allows 4 chains.
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A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
DrkAngel
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Posts: 4508
Joined: Dec 15, 2010 11:14 am
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Re: Snow Beast Refurb

Post by DrkAngel » Jan 06, 2018 11:53 am

Was able to get a 16" pipe wrench on outer ring, After stomping on wrench I finally started it turning by pounding with large rubber mallet.


Image

Freewheel promptly fell apart.
freewheel.jpg
freewheel.jpg (103.56 KiB) Viewed 386 times
Disassembled hub and bearing races seem smooth and in good condition.

hub.jpg
hub.jpg (119.01 KiB) Viewed 386 times
I am faced with a dilemma!
Spokes are rusted and frozen, rim is worn with a bit of dishing.

spokes.jpg
spokes.jpg (67.97 KiB) Viewed 386 times
But wheel is still true with no dents or wobble.

Do I cut all the spokes, replace rim and build new wheel?
or
Simply and easily, put back together with new bearings?

Decided to quick rebuild as spare ...
Will keep handy for quick-temporary use.

Soaking all nuts-n-such in vinegar, so I have time to change my mind.
1 week soak in standard vinegar seems to clean up rust nicely!
Wire brush to remove resultant black scale.
Important to protect bare metal after cleaning!
Will start to surface rust immediately!
I clean-polish with steel wool and pastewax, chapstick works in a pinch.
Furniture polish with wax?
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

markz
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Re: Snow Beast Refurb

Post by markz » Jan 07, 2018 4:39 pm

Dirt and Grime and Rust give your SNOW BEAST "Character"
I must say I am digging it.

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DrkAngel
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Re: Snow Beast Refurb

Post by DrkAngel » Jan 07, 2018 10:40 pm

.
...
Patina ! ... ?
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
DrkAngel
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Location: Upstate-Western-Southern Tier NY. USA

Re: Snow Beast Refurb

Post by DrkAngel » Jan 08, 2018 7:01 pm

Damn ... starting to like my Snow Beast ... too much?

Geared low >> volted up, with good battery!
Roads are clear enough that I can open it up, has great acceleration till near 18mph, then settles up to 21+.
The fine product of gearing for specific application. Spoiling me, might rig a cruiser similarly for Summer use. Fun, is that it is running off a restricted current controller, 24V oem was 35A, swapped for a 36V 25A. EBikes.ca simulator shows 37V pushing MY1018z towards 750w w/35A controller!

Probably 6000+ 36V hard miles on the Beast, motor still feels smooth and strong. The original MY1018z, not the quieter XYD-16, has more power and whines like a banshee ... studded tires adding their own sonic signature!
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
DrkAngel
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Re: Snow Beast Refurb

Post by DrkAngel » Jan 13, 2018 11:51 am

Last major item is derailleur, cables and , now, shifter.
Shifter was previously "repaired" with duct tape :oops: .

Problem is ... oem shifter is a 7 speed "reverse built" for left side placement, placing a "normal" 7 speed shifter on the left side produces an awkward direction shift.
So, I have decided to test various trigger shifters. Will try right side, inside brake lever but also left side in upside down position, with a possibly natural feel of thumb shifting below bar, sacrificing visual gear indication.

Cheap trigger shifters from ~$5.


Trigger.jpg
Trigger.jpg (127.76 KiB) Viewed 140 times
Last edited by DrkAngel on Jan 14, 2018 7:37 am, edited 1 time in total.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

Raisedeyebrows
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Re: Snow Beast Refurb

Post by Raisedeyebrows » Jan 13, 2018 6:32 pm

Amazing free shipping can be offered from China on a sub $5.00 item!

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DrkAngel
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Re: Snow Beast Refurb

Post by DrkAngel » Jan 13, 2018 9:12 pm

Raisedeyebrows wrote:
Jan 13, 2018 6:32 pm
Amazing free shipping can be offered from China on a sub $5.00 item!
By longstanding international agreement "postal service" fees are collected by sending country.
In a perfect world this would even out, every country would send like amounts of postage and receive equal fees.
China, seeing the benefit of accumulated foreign currency, supplements all postage leaving the country.

So, Chinese export for nearly free and the US postal service receives nothing for delivering!

I will be receiving items valued at, possibly, $20 plus $5 shipping for less than $5.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

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