Norco Aline and Kevlar/carbon tank

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Lurkin   100 kW

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Re: Norco Aline and Kevlar/carbon tank

Post by Lurkin » Jun 30 2016 2:53am

I'm a little confused.

Have you used a plastic mould, then carbon fibred the outside and kevlared the inside or
Used a aluminium mould, then carbon fibred the outside and kevlared the inside.. or?...

Is the mould staying inside or is the a crafty plan to remove it, leaving the carbon fibre and kevlar remaining?

(sounds so critical, but really I'm just very, very jelly of your work. Nice!) 8)

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izeman   10 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by izeman » Jun 30 2016 3:05am

IanM wrote:This would be a good candidate for a BBSHD. I just stuck one on my 2009 trance X1 today and like it a lot. This frame shouldn't have the clearance issues I anticipate with the trance. I'm worried I will smash the motor on a rock or log. It is nice not having 15kg of weight in my back wheel but then it sucks that I can't do power wheelies at 40kmh like I can on th FLX. Keep up the good work Sam I am keen to see how this turns out, should be a cracker.
with a bbshd you won't be able to do power wheelies @40km/h no matter how light your front is :)

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Samd   1.21 GW

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Norco Aline and Kevlar/carbon tank

Post by Samd » Jun 30 2016 3:23am

Hahahaha. I have addressed this age old conundrum as most straight thinking Ebike addicts would. By having at least two frames. Hahahaha.

I built one a few years back with a bbs02 for a chef who worked at Fed Square restaurant in Melbs. Such a beautifully balanced commuter.

And I'll build a hub version.


In my op comments I think I mentioned why they are awesome frame choices. 68mm bb and 150mm rear gives so many options.

I've actually got a LR big block here unopened for an overseas customer and I'm wondering if this might be the plan for my third donor.

Here's a pic of the old ally one I did for the Melbs guy. Please ignore the forks. He ran a bit short on spending.

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Last edited by Samd on Jun 30 2016 3:27am, edited 1 time in total.
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Samd   1.21 GW

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Norco Aline and Kevlar/carbon tank

Post by Samd » Jun 30 2016 3:25am

Sorry lurkin, almost forgot. No I did away with the plastic cage once I discovered the simplicity of Waterjet. The 3D cage was very handy for checking the size and look in my own shed though before committing to metal.

I've convinced a few guys in the uk on ES Facebook to hack Norcos. Nothing else can touch that rear end patent.

I like this flat ally sheet idea. Easy to mail a sheet around the world for little cost.


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Quokka   1 kW

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Re: Norco Aline and Kevlar/carbon tank

Post by Quokka » Jun 30 2016 4:31am

Subd. Looks sick sam :shock:
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teslanv   100 MW

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Re: Norco Aline and Kevlar/carbon tank

Post by teslanv » Jul 03 2016 11:30am

Subscribed.
DD Hubs, Batteries, Controllers & Custom Ebikes.
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spinningmagnets   100 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by spinningmagnets » Jul 03 2016 11:48am

LR big block here unopened for an overseas customer and I'm wondering if this might be the plan for my third donor
Hope the customer posts pics!

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Samd   1.21 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by Samd » Jul 03 2016 5:30pm

Coated the outer in a layer of West System epoxy yesterday and will give it a bit of a wet rub with fine sandpaper on the mating surfaces in the next few days. I'd better degrease and rough up the mating surfaces on the frame too..
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cal3thousand   1.21 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by cal3thousand » Nov 29 2016 2:32pm

Any updates on this Sam? Very interested in your progress.

And can I ask how you drew the flattened dimensions of the Ally box?
Get a Cycle Analyst and a Multimeter, you're still a noob if you don't have at least one of each.

Planning on posting questions or buying anything on this site? Put up your country (at minimum) on your profile. This is a worldwide forum and we haven't reached clairvoyance.

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Samd   1.21 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by Samd » Dec 25 2016 12:49am

Heya Cal i made new ribs this week. Fit much better

Niw to epoxy the gaps

Drew it in 3d and then assembled the flat outlines in inkscape. Image


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Jimboyr6   1 kW

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Re: Norco Aline and Kevlar/carbon tank

Post by Jimboyr6 » Dec 27 2016 3:15am

Sub...
Stealth bomber owner 138 livin the dream

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Samd   1.21 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by Samd » Jan 28 2017 6:29am

Image


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Samd   1.21 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by Samd » Jan 28 2017 6:30am

Image


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izeman   10 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by izeman » Jan 28 2017 12:18pm

why are some parts matt and some glossy?

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Samd   1.21 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by Samd » Jan 28 2017 3:33pm

Epoxy needs to dry then be rubbed back before next layer.


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Tats   1 kW

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Re: Norco Aline and Kevlar/carbon tank

Post by Tats » Jan 29 2017 5:37am

Sub'd

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Samd   1.21 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by Samd » Feb 15 2017 5:45am

Well i found a rare kids size. My daughter should be pleased haha.
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Mad Huey   100 mW

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Re: Norco Aline and Kevlar/carbon tank

Post by Mad Huey » Aug 10 2017 4:13pm

Guess what i just picked up for $600
Was searching the forum for best way to mount battery and of course SamD is agead of the pack again

whereswally606   100 kW

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Re: Norco Aline and Kevlar/carbon tank

Post by whereswally606 » Oct 16 2017 9:28am

Ha Thread bumped by someone being ripped off. ok not funny for that guy but anyway. I have the Norco team DH 2004 and the Norco savage. Both have vps linkage, never realised why only Norco and big hits look this way. I built the team DH for my wife before we were married. Mine is a Scott Ransom but I have to say these days I far prefer the Norco for its suspension and handling. I have as Samd mentions two Dr Bass torque arms sandwiches the 135mm axle of a hub motor that's magic pie sized but not a magic pie.

Currently I use some Macallister B&Q 36v batteries under the downtube held by a plastic printed mount. Doesn't look anywhere near as professional as this but I like the fact I can remove the power off the bike and thus its less attractive to thieves. Easier to charge too, where I can keep my eyes on the batteries.

Keep up the great work Samd
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Lurkin   100 kW

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Re: Norco Aline and Kevlar/carbon tank

Post by Lurkin » Oct 16 2017 4:10pm

It would be great to get an update on this, such a sweet battery solution 8)

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Samd   1.21 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by Samd » Oct 21 2017 3:14pm

Sure! Done a few more.

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Samd   1.21 GW

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Re: Norco Aline and Kevlar/carbon tank

Post by Samd » Oct 21 2017 3:16pm

Battery sizing perfect. This one bbshd.
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r3volved   100 kW

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Re: Norco Aline and Kevlar/carbon tank

Post by r3volved » Oct 23 2017 2:19pm

Beauty welds! :shock:

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Re: Norco Aline and Kevlar/carbon tank

Post by Coolohm » Oct 23 2017 9:19pm

Cool man!

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1000w   1 kW

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Re: Norco Aline and Kevlar/carbon tank

Post by 1000w » Oct 24 2017 9:14pm

Samd this is a lovely build well done.
A while back I stumbled onto one of these Alines and just had to have it when Timma (Paul) put it up for sale.
I've also done a battery box frame mod, just getting the battery built ATM by Cellman, and then should be on the road, can't wait.
I have a small build log if you're interested, I'll be watching your one closely. :D

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