spinningmagnets: Yes, that's the one!
Impressive chopter on H202, and they say Lipo batteries are flammable
beast775: Yes, a lot of cold swetting there. Inside headtube were originally 2 big holes already. Those are welding aids maybe, I've seen this inside a lot of frames. I just had to remove the badge and drill the outer one. Started with 3mm, then increased gradually to 18mm. Hole is now eliptical 20mm-22mm in diameter. Battery 8s packs are eliptical 19mm-21mm in diameter. Took one new picture (picture nr 10) to show that the big hole was not the only one drilled. There are two 10mm holes inside to accomodate 5 pieces of 2x0.75mm^2 wires emerging from the 8p packs, and additional PAS sensor that is not yet in place. USB cable and throttle cable will also be hidden inside the top tube off corse.
Dremel (my favorite tool besides my Makita) did fantastic work here! Fem analysis says chassis is as stiff as before. My tests on Interceptor show 1 year of use without failure on a much weaker frame, so this should be safe. There are massive welded plates outside that are taking the majority of the workload. This is the peak inside the headtube:
Choosing the motor
Choosing the motor was not an easy task. Possible choices:
1. Central motor. Mass in the right place. Estetically unappealing.
2. Big DD motor like Muxus 3000 or the like: too heavy for the full suspension (rear suspension is air, no coil to keep the mass down). Too powerfull for the batteries, I don't want to ebike around with the aux pack conected all the time.
3. Mac 12T is too heavy, its 4.2Kg. It's peak power would match the batteries perfectly.
4. Q128H is heavy at 3kg.
5. Xiongda 2 speed is very interesting, but it is also 3kg.
6. Oil cooled Q100H revved at 7300rpm@76V thru the 15.7:1 reduction seems the only logical choice. Mass: 2224 grams without the freewheel. The only problem with this motor is that I already own 2 of them, both are oil cooled and revving 4k+ rpm@55V. I really hoped to try something new this time... At these revs, it will explode like a supernova, or make it's own gravity field. Or both
. I'm looking forward to the first test... EDIT: It didn't explode.
Meanwhile I'm waiting for the parts, take a look on how to increase the power 10-times, great youtube video done by subcooledheatpump@youtube: