Andrew's NYX carbon frame + cromotor. full fat build log

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Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 02, 2015 5:40 pm

[size=150]finished the build as of 24th Dec 15. Scroll down for photos[/size]

NYX Carbon frame/cromotor build log.

I am stepping into new territory, up until now i have built a number bikes with small motors for commuting with the most powerful setup being a magic pie in a full suspension mtb frame for playing in the woods, but this has been handicapped by having limited battery space and amp hour. So i thought it was time to get serious and spent all my hard earned savings on an ebike frame and full fat motor.
The frame has just landed here in wet and windy Wales coming from the land of the Maple, and what a work of art it is......
As i type this, I am still waiting on a headset and freewheel to arrive but most other things needed for the build are at hand. Not sure what size rear shock to get yet. As this will have a big impact on the geometry and performance of the bike i am leaving it until the rest of the bike is done so i can get a better judgement on length.
Here are a few pics....
Last edited by brumbrum on Dec 24, 2015 8:20 am, edited 4 times in total.

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 02, 2015 5:54 pm

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 02, 2015 6:11 pm

Got the cromotor laced into a fat 1.85 x 17 moto rim and bought a cheng shin also known as CST 3.00" dual sport tyre. It wasn't too bad getti g on the rim with large tyre lever but it left a few scratches on the rim, but hey ho the bike will used on rough terrain so it aont going to be pretty for long. I sat the motor on a car tyre which helped when seating the moto tyre.
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This last picture shows it against a 24x3" halo contra fat tyre
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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 02, 2015 6:21 pm

The cro is said to weigh 11kg
In the moto rim with spokes it weighed 13.3kg
With the tyre and inner tube and air 16.6kg

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by Sean9002 » Dec 02, 2015 7:21 pm

so far, so pretty!!

Spray a bit of Windex on the tire when mounting...evaporates away and helps as a lube!
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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by drew12345 » Dec 02, 2015 7:22 pm

Very nice! Love the badge.

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 03, 2015 4:16 am

Sean9002 wrote:so far, so pretty!!

Spray a bit of Windex on the tire when mounting...evaporates away and helps as a lube!
Funnily enough i only remembered to lube right near the end - when it was needed. Some soapy water definitly helped and a heat gun to soften the rubber a little. Investing in a cheap long tyre lever takes the pain and frustration out of the equation for sure.

I had a play around yesterday mounting the motor onto the frame and had the same age old issues of......
Wires too close to the moving disc rotor
Not enough clearance for the brake calliper mount
Disc rotor bolts being too long for the cromotor threaded holes - this in particular drove me loopy! As adding a spacer behind the rotor meant even less space for the brake mount. Tried cutting down the tiny bolts and made a hash of it. Went to a local bike shop and they had no shorter bolts. In the end i found some from an old build in a draw full of bits, these had large allen heads which caused even more clearance issiues for the wires coming out of the cro. I then stripped one of the allen heads :evil: eventually got it back out. Tried another bolt (a star headed one this time) in the cro to see if it was short enough and it stripped too and got stuck in the cro which led to 30 minutes of sawing, swearing, shouting.... Eventuallly brute force with some pliers enabled me to get the bolt back out.
In short, as usual, to get a rear disc brake mounted means lots of trial and error and repositioning of parts, and it looks like i will have to be quite creative channelling the exit route of the fat cro wire bundle.

I have to be careful not to stretch the rear swingarm too much for axle mount as it is a concentric bottom bracket.

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 03, 2015 5:05 pm

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Just waiting for a headset now for the rest of the build.

Next, to test the motor and controller and wire combos.

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by Jonboy » Dec 04, 2015 3:53 pm

Looks mint!! "Big Guy" :lol: If you get the head set in or plan on doing an hour on it over the weekend gis a shout, if I can I'll bomb down & muck in ..

Just want to perv on the carbon really !!! :P

quick edit: Arghh.. no probs with the crank fitting then, are all the rings still on?

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 04, 2015 4:34 pm

Jonboy wrote:Looks mint!! "Big Guy" :lol: If you get the head set in or plan on doing an hour on it over the weekend gis a shout, if I can I'll bomb down & muck in ..

Just want to perv on the carbon really !!! :P

quick edit: Arghh.. no probs with the crank fitting then, are all the rings still on?

Hiya Jon, a helping hand is always appreciated , the headset has not arrived :cry: and there have been many more woes with the build, i took the whole thing apart this evening to start again due to continuing issues with the rear brake fitment. The new cromotor disc rotor mount face (that you pointed out was different to yours) will not allow the hope rotor to sit flush. I thought i had a warped rotor as i pained to align everything up to get the rear brake to work. After continued filing of the mount adapter bracket, filing the caliper mount holes, trying numerous other things, i took it all apart to check the rotor on a normal bike wheel and it was perfectly 'true' and not warped at all. I will try and purchase anew rotor tomorrow.
The mount bracket has been raped of most of its aluminium and the mount is now worringly thin lol. I have started considering filing the face of the IS mount on the frame itself to gain a couple of millimetres....... Any idea where there might be a machine/metal working shop where i could get that done??

I also cut my chian too sort today.. Dooh, and i will also need a chain tensioner as the bolt on chain tensioners supplied with the frame cannot be used as the cromotor wires are in the way. If the wires of the cro exited through the end of the axle then the tensioners could be used but they do not.

So all in all, i am back to where i started.... Nothing done, and still a brake clearance issue. :|

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 04, 2015 4:38 pm

the chain ring. I took the large ring off and put on the black bash ring you see in the photo above. The smallest ring is also unbolt-able so eventually i will put an inner bash ring on too and just use the middle 32t ring to make a 'bashwich' :lol:

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by Jonboy » Dec 04, 2015 5:13 pm

Chill bro.. i'm sure the brake issue is a pig.. deep breath! new day 2moz I may be able to help with the machining :wink:

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 04, 2015 5:19 pm

Jonboy wrote:Chill bro.. i'm sure the brake issue is a pig.. deep breath! new day 2moz I may be able to help with the machining :wink:
Yep, had enough for now! I would be a very happy bunny if i could get the brake mount on the frame faced, that would solve everything!

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 16, 2015 12:41 pm

Update. Trying to get the cromotor wires to fit through the nyx dropout has been a right royal pain in the buttocks. Had to do some major butcher surgery.

Big big thank you to ES member Jonboy who came to the rescue with right tooling for the job...
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The cromotor now seems to have a raised face where the disc mounts which leaves no room for a brake caliper bracket so i will be mounting the bracket on the outside surface of the swing arm....

Again, had to take drastic action to get the bracket to sit further in towards the disc...

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Now i am just waiting on a headset that should have been sent out from Canada with the NYX frame, but wasn't.

I tested the wire combos with a lyens 18fet controller and all the phase and hall colours match with the Cro.
Next i will try and match up the spare set of hall wires that come with the cro.

Its been a mission!

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 18, 2015 11:55 am

For those interested...

Spare hall wires on the cro matched with a lyens controller, colours are as follows...

Cromotor/controller
Brown to black
Orange to red
Grey to yellow
Purple to green
White to blue

Pulls at little over 2 amp unloaded at WOT

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 24, 2015 8:07 am

I have pretty much now finished the build. The next puzzle to conquer is how to arrange the battery, wires and controller comfortably so everything is snug in the frame.
The only minus point at the moment, the bike has a turning circle larger than Saturn so i may have to raise the fork legs and crowns to sit higher which is a shame as it will change the geometry of the frame and fork angle which is great at present, but i suppose being able to turn when doing 50+mph is more important.

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by Lurkin » Dec 24, 2015 10:07 am

Gotta love those mudhugger rear guards. Smart design and functional, surely more durable than crud racer equivalents.

Wait, was that mudguard envy?!! :oops:

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 24, 2015 10:54 am

Lurkin wrote:Gotta love those mudhugger rear guards. Smart design and functional, surely more durable than crud racer equivalents.

Wait, was that mudguard envy?!! :oops:
Yeah, well recognised, the mudhugger has done its job well since on my last bike. I highly recommend them. Surprisingly secure using some zip ties.

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by pucksterpete » Dec 24, 2015 1:37 pm

What version of the mudhugger do you have?
Optim Alp Hardtail with MXUS Motor
20S 2P Turnigy 5.0 Hard Case
Top speed 38mph tops :)
Hyena Special
https://endless-sphere.com/forums/viewto ... 97#p585997
-------
Excelsior/Strong GTS with Cromotor
24S 3P Turnigy 5.0 Hard Case
Top speed so far 53mph
https://endless-sphere.com/forums/viewto ... =6&t=46993

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 24, 2015 4:20 pm

pucksterpete wrote:What version of the mudhugger do you have?
Not sure what exact version, i have had it a few years. It is just the standard rear.

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by Jonboy » Dec 25, 2015 4:35 am

SWeeet.. slam those batteries in lets get up the hill!! :twisted: Merry Christmas Bud...

Santa came for my young un!!!
Attachments
20151225_093212[1].jpg

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by Jonboy » Dec 25, 2015 5:59 am

Building..
Attachments
20151225_105307.jpg

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by pucksterpete » Dec 25, 2015 7:05 am

Hey Jonboy we have the same house shoes.

Image
Optim Alp Hardtail with MXUS Motor
20S 2P Turnigy 5.0 Hard Case
Top speed 38mph tops :)
Hyena Special
https://endless-sphere.com/forums/viewto ... 97#p585997
-------
Excelsior/Strong GTS with Cromotor
24S 3P Turnigy 5.0 Hard Case
Top speed so far 53mph
https://endless-sphere.com/forums/viewto ... =6&t=46993

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by brumbrum » Dec 25, 2015 12:39 pm

I cannot believe i've had my build thread hijacked with pictures of christmas slippers :roll:

I Went for a test drive today and flipped the bike! It shaved a whole inch off the tail of my mud guard.. Lol thankfully it wasn't an inch off my chin. my throttle is very twitchy at present.

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Re: Andrew's NYX carbon frame + cromotor. full fat build log

Post by Jonboy » Dec 25, 2015 1:35 pm

Take your time fella.... :lol: don't damage you or the bike.. it's to early in our hols!

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