Brake's Phatrod Cruiser Build

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Brake   100 W

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Location: Spokane, Wa

Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:02pm

Hello everyone,

First of all I would like to thank Endless Sphere and all of the members, this project would not exist without you. Special thanks to Xenodious, DoctorBass, ZombieSS and AndreyM for all the components and information. So, it all started during the winter, reading and sourcing parts. The goal of the build was to create a beach cruiser bar bike that could get me up the hills and provide enough power to make riding fun. The bike I converted was an Electra Straight 8. An all aluminum bike with 24' by 3' tires. Cromotor, Adappto Max E, and Konians for the electrical, a motorcross rear rim and Harley front tire for the wheel. Laced using Holmes custom spokes. Thank you all for providing the parts and components to make this bike possible.

I will primarily make this a picture build with some explanations as I go. Let me know what you guys think.

Brake.

Picture to come!
Last edited by Brake on Oct 10 2014 8:38pm, edited 1 time in total.

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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:28pm

ImageUploadedByTapatalk1401755258.459888.jpg
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Couldn't find many good before build pictures. This is it though. Trying to figure out how to modify it.

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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:31pm

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The Cromotor. Dual halls, temp sensor and all.
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Makita packs ready to take apart.

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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:33pm

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Exciting to find so many good batteries.
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10p packs.

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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:35pm

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Kept the packs somewhat separate in case there were issues.
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Getting the wheel figured out.

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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:39pm

I made wood forms. Annealed the 6061 t6 and beat it into shape. Had to anneal several times. This was tough.
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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:43pm

Got the wheel assembled after a little rim treatment and powder coating the Holmes spokes.
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Here's a comparison of the original and the 17" MC rim.
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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:47pm

Front wheel had to be redone to include a disc brake.
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Went with a 203mm shimano Ice disc.
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Brake   100 W

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Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:50pm

Avid BB7s mechanical caliper. Machined the mount, installed and ran the cable inside the fork, head tube and handlebars. This was tricky!
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Brake   100 W

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Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:54pm

On to the major stuff now. How do I fit this 155mm Cromotor onto the bike.
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These are 1" by 2" 6061 T6 with dual clamping bolts.
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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 7:58pm

Rear framework all out of 1" 6061 about 0.175" wall thickness.
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Also made a temporary rear axle for jig purposes.
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The scary part!!
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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 8:02pm

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Motor wire runs through the left clamping dropout then up through the lower tube.
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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 8:05pm

Had to get a Tig welder. :)
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Added a lot of framework here. You can see where the motor wire will come out.
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Brake   100 W

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Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 8:08pm

The frame. Extended wheelbase 4"
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Dark Knight   100 W

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Re: Brake's Phatrod Cruiser Build

Post by Dark Knight » Jun 02 2014 8:10pm

Looking good so far - can't wait to see the finished product. Impressed with your attention to detail - running wires inside frames etc.
Good luck getting it completed and up and running!

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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 8:10pm

Time for the battery housing. CAD
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Brake   100 W

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Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 8:13pm

Lined the inside with rubber.
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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 8:15pm

All battery housing components wrapped with flat and gloss black vinyl.
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Little hot rod touch.
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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 8:19pm

Adappto max E mounts behind seat post. Air scoops in front of battery housing vent out around controller.
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This is how she looks right now.
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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 8:21pm

The little extras. Grin Tech front and rear lights.
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Thank you all.

babyhughie   100 W

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Re: Brake's Phatrod Cruiser Build

Post by babyhughie » Jun 02 2014 8:32pm

Bad friggin ass.. Attention to detail is great. What is the voltage and Ah of the battery?? Great build my friend

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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 8:49pm

Thanks, It is so fun to ride. Right now Im only running 17s 10p. Had it all set for 22s 10p but didnt end up having enough batteries for it. They will come though. So basically 70v and a 950 wh pack. I can see now that my batteries are not enough. :)

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Willow   10 kW

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Re: Brake's Phatrod Cruiser Build

Post by Willow » Jun 02 2014 9:11pm

lovely work...

pic below is my conversion of same bike.... I didn't have the heart to cut the frame - so I took a bit off the shoulder of the motore axle to fit the narrow drop-outs.

would say your bike is a lot faster than mine - must be a hoot. Hope those alu. dropouts hold up to that beast of a motor.

S.

[moderator edit to add link to build-thread]
https://endless-sphere.com/forums/viewt ... =6&t=48427
retro_s.jpg
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xenodius   1 kW

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Re: Brake's Phatrod Cruiser Build

Post by xenodius » Jun 02 2014 10:00pm

Gorgeous! Didn't see ALL of those process pics, but it's nice to review the whole build-- I missed some of those subtler touches, it's just so clean. Maybe someday I'll put that much care into my build =) Can't wait to go on a ride!

I haven't asked-- do you smoke? Cause I have a couple very nice cigars if you feel like celebrating your craftsmanship... maybe with some Balvenie 30 year =)

Nice close-ups of those dropouts. So awesome. I've been converted to clamping, regen is great for saving pads especially when you have an efficient controller and a motor that will almost never overheat. Especially on long hills.

The only time I hit my temperature limit on my cromotor was after doing repeated 100-amp acceleration runs, and 200-phase amp regen braking over and over and over just to see how fast it raised. It took me almost ten minutes of that before I noticed that the controller had limited my power to around 4,000 watts, where it stayed for the next few runs... that was with a 100C limit. The temperature bar is almost never in visible range! It's such a beast.

This is such a perfect city bike. It's so clean it's reasonably stealthy, too!

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Brake   100 W

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Location: Spokane, Wa

Re: Brake's Phatrod Cruiser Build

Post by Brake » Jun 02 2014 11:58pm

Thank Willow, your bike is amazing. Saw it before and it was an inspiration for this project. Nice work.

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