upgrade Axle set for MXUS 3000 V2

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madin88   1 GW

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upgrade Axle set for MXUS 3000 V2

Post by madin88 » Sep 15 2015 7:52am

Hello,
from now on you can buy a really strong Axle for the popular MXUS 3000 V2 from me. this axle makes it really easy to install larger phase wires what is highly recommended for the 3T and 4T if you going to push large currents.
as the brake side cover needs to be machined to make the necessarily larger bearings fit, it will be included as well.
I also can supply high quality SKF or FAG brand bearings. Stock MXUS bearings are poor quality and a few owners suddenly got a locked wheel during ride beacause of bearing failure (the stator than will rub against the magnets and get stuck).

ok, now some infos:

- dropout width is exactly 150mm, the spoke flange is centered
- axle has M16 thread and 10mm flat to flat. Note: the one you see in picture has a larger diameter on flat part at wire side. this is not standard.
- it is made of strong 42CrMo4 steel (about 800N/mm²)
- two nuts for the wires with support for the bearings in the middle. there is a large radius (i believe it has R4mm) on bottom of the nuts for more stability. phase wire nut is 8mm wide and >13mm deep. hall wire nut is 6mm wide and >7mm deep. measured where the bearing sits. fitting 8mm² phase wires should be no porblem (i will use double 4mm²). splitting phase and hall cables from each other is recommended at high amps beacuse there could occur noise on the sensor wires and controller could cut out. a shielded cable would be optimal.

Lock ring and feather key can be used from stock axle.

bearing size: 2x 61806 and 1x 6003

IMPORTANT: with the larger bearings the maximum screw-in depth of brake rotor bolts is limited to 7mm. make sure they are not longer. i hope this will not be a problem. for better stay i will use loctite or some kind of other glue. with regen enabled the brake rotor anyway should be pretty long lasting so normally there should be no need to unscrew these bolts often.

if you have questions just ask!

price is 110USD for one set + shipping. Paypal accepted.
bearings are extra. price is 50USD for FAG 2RSR, and 45USD for SKF 2RSL


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Last edited by madin88 on Sep 15 2015 11:17am, edited 1 time in total.
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teslanv   100 MW

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Re: upgrade Axle set for MXUS 3000 V2

Post by teslanv » Sep 15 2015 8:59am

:)
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markz   100 GW

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Re: upgrade Axle set for MXUS 3000 V2

Post by markz » Sep 15 2015 1:00pm

What guage of phase wires can you fit?

Also, what kind of tools does one need to install this/these?
Last edited by markz on Sep 15 2015 6:07pm, edited 1 time in total.

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Re: upgrade Axle set for MXUS 3000 V2

Post by neptronix » Sep 15 2015 1:02pm

Nice. Looks like this axle alone turns it into a poor man's cromotor.
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Re: upgrade Axle set for MXUS 3000 V2

Post by Samd » Sep 15 2015 7:22pm

What's the shoulder diameter? I wonder if my 12t freewheels will fit...
http://ballaratebikes.com/

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Re: upgrade Axle set for MXUS 3000 V2

Post by litespeed » Sep 16 2015 6:39am

This is super cool.

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madin88   1 GW

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Re: upgrade Axle set for MXUS 3000 V2

Post by madin88 » Sep 16 2015 8:25am

markz wrote:What guage of phase wires can you fit?

Also, what kind of tools does one need to install this/these?
i will use double 4mm² wires so 8mm² total per phase. single 6mm² should be no problem, but single 8mm² with relatively large diameter (most high flex types) probabaly will not fit.
for removing stock axle you need a strong, 150mm long tube with minimum ID of 26mm. OD can be 40mm or more.. i have hit it out with a hammer, but a press would be optimal.
installing the new axle you can do the same way.
Samd wrote:What's the shoulder diameter? I wonder if my 12t freewheels will fit...
axle diameter at freewheel side is same (16,8mm), also the length.

i took some pics with the axle inserted into the cover. i really like that there is some much space where the wires coming out 8)

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Re: upgrade Axle set for MXUS 3000 V2

Post by markz » Sep 16 2015 11:19am

Very nice!

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Re: upgrade Axle set for MXUS 3000 V2

Post by Rix » Sep 17 2015 2:11am

Very Nice Axle! SO you got two channels, the bigger one for the phase wires and the smaller for the sensor and heat sensor wire? Also, how big did you ream out the disk brake side? Is that for a standared 6005 RS? I think that's 25mm x47mm x 12mm thick?

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madin88   1 GW

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Re: upgrade Axle set for MXUS 3000 V2

Post by madin88 » Sep 17 2015 2:59am

Rix wrote:Very Nice Axle! SO you got two channels, the bigger one for the phase wires and the smaller for the sensor and heat sensor wire? Also, how big did you ream out the disk brake side? Is that for a standared 6005 RS? I think that's 25mm x47mm x 12mm thick?
Exactly. The reason was to give the thin bearings support in the middle - without, lifespan could be worse (i think you can imagine why).
the phase wire channel has a slope downward for more space.
stock bearings are 6003 and they have 17x35x10mm. no changes on freewheel sidecover.
on brake sidecover i enlarged the diameter from 35 to 42mm and made it 4mm deeper to make 2 x 61806 bearings fit (one has 30x42x7)

If we would use only one 61806 bearing, there would not be the thing with the brake rotor screws. what do you think guys, will one bearing have enough durability?
Need to compare the load index from the spec sheets..
It is no problem to change because covers will be manufactured the next week. The 61806 bearings are very expensive so additionally it would be more favorable.
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Rix   100 GW

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Re: upgrade Axle set for MXUS 3000 V2

Post by Rix » Sep 17 2015 4:05am

madin88 wrote:
Rix wrote:Very Nice Axle! SO you got two channels, the bigger one for the phase wires and the smaller for the sensor and heat sensor wire? Also, how big did you ream out the disk brake side? Is that for a standared 6005 RS? I think that's 25mm x47mm x 12mm thick?
Exactly. The reason was to give the thin bearings support in the middle - without, lifespan could be worse (i think you can imagine why).
the phase wire channel has a slope downward for more space.
stock bearings are 6003 and they have 17x35x10mm. no changes on freewheel sidecover.
on brake sidecover i enlarged the diameter from 35 to 42mm and made it 4mm deeper to make 2 x 61806 bearings fit (one has 30x42x7)

If we would use only one 61806 bearing, there would not be the thing with the brake rotor screws. what do you think guys, will one bearing have enough durability?
Need to compare the load index from the spec sheets..
It is no problem to change because covers will be manufactured the next week. The 61806 bearings are very expensive so additionally it would be more favorable.
Double 30x42x7mm bearings is the way to go, but the roller bearings between the inside race and outside race are so small. Is that going to be a concern for long life? I don't have a lot of experience with this sized bearing, infact, I am trying to think of something I have seen it on, maybe an old throw out bearing on Volkeswagen rabbit clutch from the 70s? Again, super nice axle, BTW, now that I read the beginning of your thread, I see that you mentioned that, sorry for the redundant question.

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madin88   1 GW

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Re: upgrade Axle set for MXUS 3000 V2

Post by madin88 » Sep 17 2015 7:38am

these are the specs of the FAG bearings:

6003:
C dynamic = 6kN
C static = 3,25kN
max RPM = 14000

61806:
C dynamic = 4,4kN
C static = 3,35kN
max RPM = 8400
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Rix   100 GW

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Re: upgrade Axle set for MXUS 3000 V2

Post by Rix » Sep 17 2015 8:00am

madin88 wrote:these are the specs of the FAG bearings:

6003:
C dynamic = 6kN
C static = 3,25kN
max RPM = 14000

61806:
C dynamic = 4,4kN
C static = 3,35kN
max RPM = 8400
Well, doubling up on them makes perfect since and together, surpass the stock setup by a huge margin. Liking your axle more and more.

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Re: upgrade Axle set for MXUS 3000 V2

Post by markz » Oct 29 2015 1:02pm

You are in Austria, very nice country. I was there in Budapest...loved it. Would go again in a heartbeat. Funny, I saw a Porsche with a Florida plate when I was there.

How much to mail to Western Canada, postal code T2Y4C3.

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Re: upgrade Axle set for MXUS 3000 V2

Post by tomjasz » Oct 29 2015 1:22pm

markz wrote:You are in Austria, very nice country. I was there in Budapest...loved it.

Budapest? Austria? Oops! :wink:
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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madin88   1 GW

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Re: upgrade Axle set for MXUS 3000 V2

Post by madin88 » Oct 29 2015 2:55pm

markz, i have sent you a PM

budapest is the capital of the neighboring country hungary. the capital of austria would be vienna ;)
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Re: upgrade Axle set for MXUS 3000 V2

Post by markz » Oct 29 2015 5:18pm

:oops: Yeah, sorry, been there too. Loved them both. I'd say Vienna more so. :wink:

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Re: upgrade Axle set for MXUS 3000 V2

Post by CAP3r5 » Nov 03 2015 11:07am

I am thinking about getting the axle and upgrading the bearings while I am at it. I think I can handle the axle. How hard is it to replace the bearings? What tools are required for it?

Thanks in advance for any help/input!

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madin88   1 GW

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Re: upgrade Axle set for MXUS 3000 V2

Post by madin88 » Nov 03 2015 1:59pm

replacing the standard size bearings is not hard and there is no need for special tools. I use for instance a M8 or M10 countersunk bolt to hammer them out. for installation a hammer is enough, but never smash on the inner flange of the bearing because they could get damaged. the new bearing will better slide in with some grease added and making the sidcover hot with heatgun also helps.

the larger bearings on wire side can be installed with a flat screwdriver and a hammer. I take the tube i use for replacing the axle because it has exactly 30mm ID like the bearings have. to make the bearings hold well in the aluminum flange i apply loctite.

optimal would be:

- M8 or M10 countersunk bolt for hammering the bearings out
- tube with >30mm ID and about 150mm long for replacing the axle and installing the two thin bearings
- heatgun
- loctite for securing the bearings (i also apply this when i install the feather key and the axle into the stator)

on weekend i will post some pics of the assembly. i was able to fit double 4mm2 wires but it was not easy. i would recommend to use single 10AWG or 6mm2 wires.
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Re: upgrade Axle set for MXUS 3000 V2

Post by markz » Nov 03 2015 2:13pm

You should put at bullet point #2, and - Use old axle, and then your current statement.

Yeah, a video and/or pictures would be great. Im always hesitant, it takes me awhile to "research" and know what I am doing.

A heatgun is something I do not have, are there any alternatives?
Perhaps a regular household blow dryer, may be too weak for the required heat?
Some kind of blow-torch like one used for plumbing?
Is this to make the metal smaller to fit, then when it cools down it expands back to normal diameter?

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Re: upgrade Axle set for MXUS 3000 V2

Post by sacko » Nov 03 2015 2:17pm

I have warmed up the side cover in an oven at a low setting previously.

Put the bearing in a sealed bag in the freezer for 30 minutes prior.

The bearing will drop straight into the cover.

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Re: upgrade Axle set for MXUS 3000 V2

Post by markz » Nov 03 2015 2:28pm

Bag, Freezer....how long? overnight?
then
Oven, low......how long?

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Re: upgrade Axle set for MXUS 3000 V2

Post by MrDude_1 » Nov 03 2015 2:31pm

I just did this the otherday with the cush drive of my motorcycle.
The lazy way I do it is:
place bearing in freezer. wait until tomorrow. (or atleast a few hours)
put the aluminum plate (with nothing on it) on the grill, keep the grill on low heat (oven works too, but please NOT the house oven) cook at 280-300* if painted, 500-600* if not painted (hotter is better, but too hot burns paint) You want the item at that temp, so give it a few mins... 15-20 is good. aluminum heats up fast.

Carefully pull it from the grill/oven, and plop the bearing in place. have a piece of wood and a mallet handy if needed, but should go in without much resistance.... if its 600 and the bearing is frozen, it will literally fall into place.

Note, it doesnt take long for the bearing to heat up and stick...(small thermal mass)... so work fast. it will take a bit for the metal to become cool enough to touch.
Warning:This post is being read via light, a substance known to the state of California to cause cancer.

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Re: upgrade Axle set for MXUS 3000 V2

Post by MrDude_1 » Nov 03 2015 2:34pm

one warning.. I dont know the type of paint on your motor.. I work with unpainted cush drives and hubs.... so if you scorch the paint doing it my way, you may want to do a sand/scuff and spray before putting it back together.
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Re: upgrade Axle set for MXUS 3000 V2

Post by sacko » Nov 03 2015 3:01pm

Sealed bag in the freezer for 30-40 mins

Fan oven 90c for 10-15 mins.

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