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Norco Aline and Kevlar/carbon tank

Posted: Jun 10 2016 6:20pm
by Samd
I collect these frames now. The rear end far surpasses a single swinger offroad and is protected by a patent.

I've converted a few with aluminium but figured it was time to get my composite on.

Carbon is conductive so I'm thinking Kevlar inside (flame retardant too) and carbon external. Image


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 10 2016 6:22pm
by Samd
I can fit a couple of kwhr of 18650ga and the width will be so narrow. Image


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 10 2016 6:23pm
by Samd
3D printing a form for the composite layup. I have a box of dp810 to bond the final result to the ally. Image


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 10 2016 6:25pm
by Samd
The joy of these frames is the 68mm bottom bracket and the 150mm rear which can have 8mm Waterjet plates inserted inside to take a 135mm hub.

I have two frames. Might build a mid and a hub. :)


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 11 2016 7:48pm
by macribs
Sweet samd! Those bikes will be fantastic. Stealth looking. Light weight and nimble.
Looking forward to see the bikes completed.

Really like your style of building, and now with a bullet proof kevlar/carbon tank. 8)

Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 11 2016 8:20pm
by Kepler
I am liking this project a lot. Sub'd

Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 17 2016 4:07am
by Samd
My first layup on cardboard was flimsy. So I've waterjetted up a 2mm ally subframe. Kevlar liner and carbon outer. Then I'll Waterjet up a 1mm outer layer exoskeleton style other some funky Voronoi cutouts to suit the lithe shape of the donor frame.

It's flat pack ikea meets champagne ebiking.


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 17 2016 4:07am
by Samd
Image


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 17 2016 4:18pm
by Samd
Image


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 19 2016 5:22pm
by Sean9002
Samd wrote:Image


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Nice work boots boss! :lol:

Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 19 2016 5:23pm
by Samd
I like to throw something in there for the aussies. :mrgreen:

Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 20 2016 9:01am
by r3volved
That looks great!
There's one of those frames near me for $60 right now...if you didn't live on the other side of the bloody planet I would scoop it and get you to do it up!

Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 20 2016 6:53pm
by Samd
Sixty dollars! Jesus in a sundress! There's people here who'd jump at 300!
I could send you the flat sheet and a tube of dp810 for very little indeed. Then you just fold it up and sand and glue it. I could probably get it there for under $150CAD all up..

Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 20 2016 11:26pm
by Samd
I'm amazed at the lack of expense in waterjetting. Before I glue it all up I am going to get some outer plates made up (shown in red below) as well as a base door (in grey) to make the shape interesting and increase the torsional rigidity.

Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 21 2016 9:52pm
by Samd
Image

Sides done


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 21 2016 10:14pm
by spinningmagnets
Fantastic work, Sam. I'd be curious to add a few more Ah by fattening the bottom of the battery case a little, but...of course everyone has an opinion, and you on the other hand are actually doing something. Thanks for posting for everyones benefit.

$60 is an awesome deal. My immediate interest in these frames is that they can also take a mid drive well, so the builder has a choice between middie and hubbie...

The newer Norco alines seem to have an "S"-curved downtube, and the older ones have a straighter downtube. I assume from what I've read that they are built like a tank.

Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 22 2016 12:29am
by Samd
Yes like all high end DH frames they are built to take huge drops Ron.

I've got two so might fit the internal rear plates to one for a hub and the other a bbs HD.

I've kept the tank about 85mm wide so I can sling an Infineon sine wave off the bottom.

Did you see the cell layout photo above? From memory my plan took about 110 cells. That's about 1400 watthours of 18650ga.

I gotta keep the weight down for jumps. My days of riding 50kg washing machine clones are over mate ;)


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 22 2016 12:34am
by Samd
Hey Ron for the other frame shape keep an eye on this one.

https://endless-sphere.com/forums/viewt ... 5#p1191458


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 22 2016 12:51am
by Samd
A bit of dp810 on the corner joins. Image


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 22 2016 3:41am
by macribs
I tried to look at the earlier pics to see the joints of the alubox but no luck. Very clever way to fold the box, now that is origami for everyone :)
What I was trying to figure out from the pics is if there is any overlapping of the sheet metal in the joints, or if sheet metal meets in a 90 degree corner?

Trying to understand what kind of surface area is needed for the dp810 to work properly.
Folding sheet metal then gluing for bonding is ├╝ber cool.

You will weld the box onto the frame or glue it in place?

Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 22 2016 5:29am
by Samd
No overlapping with metal. I did dremel the fold lines about 1mm. Took maybe 3mins.

Yes not metal behind. But with Kevlar as below. Dp810 specialises in slippery surfaces.

I'll glue it in place. Image


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 23 2016 6:47pm
by Samd
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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 24 2016 10:43pm
by Samd
External carbon layer and Kevlar lining is making the box really sturdy. Happy so far with my experiment. Image


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 29 2016 5:33pm
by Samd
Really snug. Almost ready to bond it in. Will enamel the outer ladder brace first to stop corrosion. ImageImage


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Re: Norco Aline and Kevlar/carbon tank

Posted: Jun 30 2016 2:47am
by IanM
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.