Re-winding a hubmotor

Electric Motors and Controllers
User avatar
Andje
10 kW
10 kW
Posts: 814
Joined: Aug 25, 2010 11:03 am

Re: Re-winding a hubmotor

Post by Andje » Feb 23, 2012 9:28 am

So if you had been charging say 50$ an hour at a massive E-S discount on your labour, the commissioner would be looking at owing you 4500$ for your time, and you'd be out a further 3500$ of labour for screwing up. Kind of puts the effort in perspective :P.
Norco 125 Dirt Jumper
100v 15ah Lipo Backpack
lyens 18 fet, 100v 100 amps, R12 Regen
x5304- 95km/h
https://endless-sphere.com/forums/viewto ... =3&t=24594
Norco A-Line Park 2009
144v Kelly 300amp
5403/ future HS60
https://endless-sphere.com/forums/viewto ... =6&t=35652

User avatar
liveforphysics
100 GW
100 GW
Posts: 14521
Joined: Oct 29, 2008 1:48 am
Location: Santa Cruz, CA, USA

Re: Re-winding a hubmotor

Post by liveforphysics » Feb 23, 2012 1:39 pm

You've got two sets of magic pie side-covers. One set needs to be turned into swiss-cheese badly, the more airflow you can get across those coils, the longer and happier life it's going to have.
Each carcinogen vapor exposure includes a dice roll for cancer.

Each mutagen vapor exposure includes a dice roll for reproductive genetic defects in your children.

Each engine start sprays them into a shared atmosphere which includes beings not offered an opportunity to consent accepting these cancer experiences and defective genetics life experiences.

Every post is a free gift to the collective of minds composing the living bleeding edge of LEV development on our spaceship.

User avatar
Farfle
10 MW
10 MW
Posts: 2094
Joined: Jun 27, 2010 10:42 am
Location: Moscow, ID
Contact:

Re: Re-winding a hubmotor

Post by Farfle » Feb 23, 2012 1:58 pm

One set will be set up for air cooling, and one set will be set up for a semi-bath oil cooling.
The race bike:
24s5p 50c nano tech
Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


Team Farfle blog!! http://www.farfleselectrics.blogspot.com

User avatar
liveforphysics
100 GW
100 GW
Posts: 14521
Joined: Oct 29, 2008 1:48 am
Location: Santa Cruz, CA, USA

Re: Re-winding a hubmotor

Post by liveforphysics » Feb 23, 2012 2:11 pm

Farfle wrote:One set will be set up for air cooling, and one set will be set up for a semi-bath oil cooling.
Perfect! :-)
Each carcinogen vapor exposure includes a dice roll for cancer.

Each mutagen vapor exposure includes a dice roll for reproductive genetic defects in your children.

Each engine start sprays them into a shared atmosphere which includes beings not offered an opportunity to consent accepting these cancer experiences and defective genetics life experiences.

Every post is a free gift to the collective of minds composing the living bleeding edge of LEV development on our spaceship.

User avatar
Microbatman
1 kW
1 kW
Posts: 342
Joined: Nov 26, 2007 1:13 pm
Location: Lantana Texas
Contact:

Re: Re-winding a hubmotor

Post by Microbatman » Feb 23, 2012 5:05 pm

Great Job!!!
Brave partner holding the axel like that.
Glad he did not make a short sleeve shirt in the testing process.
Bike looks even better on vid than it does in still pics.
MotorCrystalyte X5304 20 Inch Rear Wheel DISC Brake Controller Crystalyte 48A72V4110MOSFETS
Batteries A123 24s2p
Charger Mastech 5020
Frame Azonic Steelhead
Grateful/fortunate/blessed to have the resources and family support to enjoy my ebike hobby

XLR8
100 W
100 W
Posts: 120
Joined: Aug 29, 2011 5:17 am
Location: Redland, Queensland, Australia

Re: Re-winding a hubmotor

Post by XLR8 » Feb 23, 2012 6:39 pm

Absolutely fabulous job. Well done.

User avatar
stinkler
10 W
10 W
Posts: 72
Joined: Jan 23, 2012 10:58 pm
Location: lodi CA

Re: Re-winding a hubmotor

Post by stinkler » Feb 24, 2012 6:50 pm

That is a BEAST! Better post some riding vids soon or there is goin g to be a riot.

User avatar
amberwolf
100 GW
100 GW
Posts: 24563
Joined: Aug 17, 2009 6:43 am
Location: Phoenix, AZ, USA, Earth, Sol, Local Bubble, Orion Arm, Milky Way, Local Group
Contact:

Re: Re-winding a hubmotor

Post by amberwolf » Feb 24, 2012 7:24 pm

That's a heck of a test!

I am definitely looking forward to the laced-up ride videos. :)

User avatar
Farfle
10 MW
10 MW
Posts: 2094
Joined: Jun 27, 2010 10:42 am
Location: Moscow, ID
Contact:

Re: Re-winding a hubmotor

Post by Farfle » Feb 24, 2012 8:35 pm

Uurg! The ultramotor spokes we had at the shop were too short.. Like 3mm too short, they would lace up, but it wasn't confidence inspiring. So, I challenged the LBS to see how fast they could do 36 100mm spokes :lol:
The race bike:
24s5p 50c nano tech
Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


Team Farfle blog!! http://www.farfleselectrics.blogspot.com

User avatar
amberwolf
100 GW
100 GW
Posts: 24563
Joined: Aug 17, 2009 6:43 am
Location: Phoenix, AZ, USA, Earth, Sol, Local Bubble, Orion Arm, Milky Way, Local Group
Contact:

Re: Re-winding a hubmotor

Post by amberwolf » Feb 24, 2012 9:41 pm

Hopefully you dind't tell them waht it was for, or you will probably never get them. ;)

User avatar
bigmoose
1 GW
1 GW
Posts: 3069
Joined: Aug 06, 2009 3:05 pm
Location: North coast USA
Contact:

Re: Re-winding a hubmotor

Post by bigmoose » Feb 24, 2012 9:58 pm

Sure ran smooth!! Did I miss how you are clamping your axle on the bike? ... or are two vices in order? :P
"Live simply. Love generously. Care deeply. Speak kindly. Leave the rest to God..." all the best, Dave

User avatar
Farfle
10 MW
10 MW
Posts: 2094
Joined: Jun 27, 2010 10:42 am
Location: Moscow, ID
Contact:

Re: Re-winding a hubmotor

Post by Farfle » Feb 25, 2012 5:45 am

The droupouts are a special creation of mine, ill get some pics of them when im at the shop next. In the meantime, I have a video of it running on the bike that shows the dropouts a little bit. And no aw, I never tell them what it's for. If the guy asks why I want super short spokes, I just say that i'm relacing a wheel on a kids bike.
The race bike:
24s5p 50c nano tech
Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


Team Farfle blog!! http://www.farfleselectrics.blogspot.com

User avatar
Farfle
10 MW
10 MW
Posts: 2094
Joined: Jun 27, 2010 10:42 am
Location: Moscow, ID
Contact:

Re: Re-winding a hubmotor

Post by Farfle » Feb 25, 2012 12:00 pm

sorry guys, no riding video yet, how bout a walkaround?

The race bike:
24s5p 50c nano tech
Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


Team Farfle blog!! http://www.farfleselectrics.blogspot.com

User avatar
Alan B
100 GW
100 GW
Posts: 7068
Joined: Sep 11, 2010 7:43 am
Location: San Francisco Bay Area, USA
Contact:

Re: Re-winding a hubmotor

Post by Alan B » Feb 25, 2012 12:06 pm

Very nice!

Any idea what that 'clicking' is?

User avatar
Farfle
10 MW
10 MW
Posts: 2094
Joined: Jun 27, 2010 10:42 am
Location: Moscow, ID
Contact:

Re: Re-winding a hubmotor

Post by Farfle » Feb 25, 2012 12:26 pm

Alan B wrote:Very nice!

Any idea what that 'clicking' is?
It didnt do it before i varnished the stator, and now it does, so im guessing that its just the dang varnish rubbing on the mags. It has self-clearanced quite a bit, and im hoping that with some more miles that it goes away, if it doesn't I'll pop it open and sand it.
The race bike:
24s5p 50c nano tech
Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


Team Farfle blog!! http://www.farfleselectrics.blogspot.com

User avatar
ohzee
10 MW
10 MW
Posts: 2263
Joined: Jul 20, 2011 1:13 pm
Location: Columbus Ohio USA

Re: Re-winding a hubmotor

Post by ohzee » Feb 25, 2012 12:28 pm

Looking good.. I like how the braided wires look as well.

Can't wait for that puppy to be laced up.

zombiess
1 GW
1 GW
Posts: 3294
Joined: Feb 01, 2011 2:16 am
Location: Ventura

Re: Re-winding a hubmotor

Post by zombiess » Feb 25, 2012 12:59 pm

ohzee wrote:Looking good.. I like how the braided wires look as well.

Can't wait for that puppy to be laced up.
Not only do they look good, they reduce the overall induced inductance into the hall wires running near them because they are no longer parallel. At least that's what Farfle likes to tell me, but I know he just really loves to braid :mrgreen:

User avatar
nicobie
10 MW
10 MW
Posts: 2430
Joined: Aug 07, 2008 1:48 pm
Location: Central Coast CA,USA

Re: Re-winding a hubmotor

Post by nicobie » Feb 25, 2012 1:25 pm

Awesome dropouts! I can't see any spinout problems in your future.
Image

May your tote always stay tight and your edge eversharp :wink:

my eTownie build thread: https://endless-sphere.com/forums/viewto ... =6&t=23701

User avatar
stinkler
10 W
10 W
Posts: 72
Joined: Jan 23, 2012 10:58 pm
Location: lodi CA

Re: Re-winding a hubmotor

Post by stinkler » Feb 25, 2012 3:07 pm

Good lord that thing is going to rip.
What size rim are you thinking for that fat bastard?

User avatar
gensem
1 MW
1 MW
Posts: 1673
Joined: Apr 01, 2011 5:28 pm
Location: Sao Paulo - Brazil

Re: Re-winding a hubmotor

Post by gensem » Feb 25, 2012 9:49 pm

Alan B wrote:Very nice!

Any idea what that 'clicking' is?

the noise is very much alike the one I have... and im almost sure its the hub bearing...
will WOT alot to see if it goes away... dont really wanna open it.
Justin we really appreciate what you did!

User avatar
Farfle
10 MW
10 MW
Posts: 2094
Joined: Jun 27, 2010 10:42 am
Location: Moscow, ID
Contact:

Re: Re-winding a hubmotor

Post by Farfle » Feb 25, 2012 9:57 pm

heres some pics of the dropouts, not welded in yet:

Image

Image

Image

Image
The race bike:
24s5p 50c nano tech
Badass custom mofo outrunner 205x177mm 26kv
Peak power in : 420A at 87v
Peak power out: 34 Hp and 105ft/lb

Build to last...
"It will be assaulted by the elements, It will be ravaged by time and it will be destroyed by the user. BUT, if you Stick to the little rules: K.I.S.S., Overbuild everything, and test, review, revise, repeat. It will last"


Team Farfle blog!! http://www.farfleselectrics.blogspot.com

User avatar
bigmoose
1 GW
1 GW
Posts: 3069
Joined: Aug 06, 2009 3:05 pm
Location: North coast USA
Contact:

Re: Re-winding a hubmotor

Post by bigmoose » Feb 25, 2012 10:01 pm

Farfle, I sure like your dropout solution! Absolutely, positively solved it. Plenty of wire room and NO possibility of rotation.
"Live simply. Love generously. Care deeply. Speak kindly. Leave the rest to God..." all the best, Dave

User avatar
liveforphysics
100 GW
100 GW
Posts: 14521
Joined: Oct 29, 2008 1:48 am
Location: Santa Cruz, CA, USA

Re: Re-winding a hubmotor

Post by liveforphysics » Feb 25, 2012 10:29 pm

Farfle, you are a rockstar. Love it!
Each carcinogen vapor exposure includes a dice roll for cancer.

Each mutagen vapor exposure includes a dice roll for reproductive genetic defects in your children.

Each engine start sprays them into a shared atmosphere which includes beings not offered an opportunity to consent accepting these cancer experiences and defective genetics life experiences.

Every post is a free gift to the collective of minds composing the living bleeding edge of LEV development on our spaceship.

User avatar
Arlo1
100 GW
100 GW
Posts: 8538
Joined: Apr 26, 2009 10:36 pm
Location: Nanaimo BC Canada
Contact:

Re: Re-winding a hubmotor

Post by Arlo1 » Feb 25, 2012 11:16 pm

Yup awesome dude!
My Leaf motor controller build. viewtopic.php?f=30&t=63982&p=963227#p963227
My YSR build http://www.youtube.com/watch?v=BRo8r5g4NBg
RC and most types of Lithium batteries you MUST know your individual cell voltages charging and discharging.
Don't keep them were you cant afford smoke or fire!
Never above 4.2v never below 2.7v EVER!!!
HI power controller design. Game Changer
http://www.undergroundelectrics.ca/

User avatar
parabellum
1 MW
1 MW
Posts: 1978
Joined: Nov 19, 2010 9:55 am
Location: Dominican Republic, north.

Re: Re-winding a hubmotor

Post by parabellum » Feb 26, 2012 9:15 am

Farfle, this monster is bomb proof in every direction. If this is the result of simple "Re-winding a hubmotor", your potential must be inexhaustible. Awesome work.

Post Reply