HPC Revolution XXX

Discussions related to motors other than hub motors.
This includes R/C motors, botttom bracket, roller and geared drives.
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Wheazel   10 kW

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Re: HPC Revolution XXX

Post by Wheazel » Sep 27 2015 9:22am

Looking good! How much clearance to the pedal arms?

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Sep 27 2015 9:35am

Approx. 16mm on one side, 10mm on the other. With the 148mm BB, there was good amounts of room. Thanks for bringing that to my attention Wheazel! I will have to finalize any spacers in centering that 3mm difference before the chainline alignment.
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macribs   1 GW

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Re: HPC Revolution XXX

Post by macribs » Sep 27 2015 9:36am

Leeleeducati wrote:Also those carbon covers were "samples" HPC sent me as they were at the time trying to source a manufacturer that could provide the quality finish they wanted. You can't see in the pics, but there are some areas that have fibers showing.

A cheap a fast solution could be to just order pre made carbon fiber panel and cut to size and fit. There are various vendors to choose from and you might even have one close by. CF is "cutable" but you need hardened tools for the job and preferable vented mask or cut outside. The microdust from cutting CF panels is not something you would have in your lungs.

Bike is stunning. Can't wait to see it completed. Keep up the great work.

Dunkenb   100 mW

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Re: HPC Revolution XXX

Post by Dunkenb » Sep 27 2015 3:22pm

Looking good. For the cooling vents ,how about having a scoop through the headstock like on sports motorbike? You could mount the dash and a light on it too? :shock:

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motomoto   1 kW

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Re: HPC Revolution XXX

Post by motomoto » Sep 27 2015 7:11pm

That is pretty F**king clean dude. I was skeptical at first, but it looks like you have thought it through. You will need
a pretty good moto guy to ride that thing in the dirt. It will spit the average guy off with that much torque !!!

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Sep 28 2015 9:06am

Same here, when I first held that 160 in my hand I wasn't sure it was even going to fit but that part worked out well. Real world and CAD are two very different things. I figure all the heavy lifting is done, just some PITA chain ring connections. I thought I might be able to get away with off the shelf adapters for front chain ring and rear cog but these too will involve more machining and custom parts. I'm still very limited with the way the swing arm is designed and how big a rear cog vs. front I can put on there (same story as the RN01). As for torque, I'm hoping for lots. Of course with a good controller I will vary/limit the ramp up but I came off liter bikes so I'm used to 200hp... but sadly the bikes all got traded in for a minivan after the kids came :)

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speedmd   100 MW

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Re: HPC Revolution XXX

Post by speedmd » Sep 28 2015 11:08am

Nice looking build. Have you settled on a controller and battery voltage. Do we know the KV. If you go too low a ratio you may need to add a few inches to the swing arm length to keep the front end down. :shock: Has me thinking of a moto style saddle on my setup so I can slide forward when need be.

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etard   1 MW

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Re: HPC Revolution XXX

Post by etard » Sep 28 2015 12:48pm

Elegant! Is it still cheaper than a Stealth? It will certainly be better!
Four wheels moves the body, Two wheels moves the soul
Thanks to Justin @ http://www.ebike.ca He brings the soul to ES

hi-powercycles   100 W

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Re: HPC Revolution XXX

Post by hi-powercycles » Sep 28 2015 3:02pm

Awesome looking build. You really don't mess around, do you? Your production carbon panels are being sent out today!

-Chris

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Sep 28 2015 3:11pm

Thanks Chris! I have to say and not just cause I own one, but hands down, best looking frame out there, you guys did an excellent job! Aluminum frames are the best for mods and customizing, makes it easy for guys like me to get creative.

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Sep 30 2015 10:35am

These circles are becoming a theme... Here's the partially completed chainring carrier. I have a RaceFace 30T on order but until I get it, I won't be able to finalize the front spacing. The 30T's have slightly different geometry in the width. Once I know where the holes are I'll have to put this part on the "swiss cheese" weight loss program and drill a bunch of holes. This part alone is surprisingly heavy but I guess a pound here or there is inconsequential at this point.
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Miles   100 GW

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Re: HPC Revolution XXX

Post by Miles » Sep 30 2015 1:05pm

Hi Lee,

I think you should consider additional bearing support for the ENO freewheel. Otherwise, it's bearing isn't going to last very long....

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Sep 30 2015 1:32pm

Good call. I was thinking this one will be sacrificial for the time being. I had ordered it just when Sick Bike Parts came up with the dual bearing design, not even sure it's released yet? I'll test with this one and when it dies I'll go for the "Ultra" and maybe design something stronger around that one if I need to? Pablo, how are the tests going? Need me to put one through a higher power application?

Here's the link to the Ultra, I even left the .18" clearance difference on the Ultra vs. this one for future upgrade.

https://endless-sphere.com/forums/viewt ... o#p1044070
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Miles   100 GW

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Re: HPC Revolution XXX

Post by Miles » Sep 30 2015 1:51pm

Cool. I didn't know it was ready, if not yet available.

We had a long discussion on this subject a while back:
https://endless-sphere.com/forums/viewt ... 28&t=25153

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speedmd   100 MW

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Re: HPC Revolution XXX

Post by speedmd » Sep 30 2015 3:28pm

How much torque does this beast have? You certainly will be testing that free wheel. Will be interesting to see how long it lasts.

Did it work out to around 40KV? No load around 2900 rpms on 72 volts. Looks to be a great motor with a near perfect reduction ratio possible with standard chain items.

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Sep 30 2015 3:50pm

Yes KV is just a touch under 40. The final reduction will be around 1:5. I wanted to stick with standards when it came to freewheel and chain rings and those lower limits bottom out at 13T freewheel and 30T chainring for 104 BCD. The rear cog carrier I'm hoping to work on tonight and that will be 104 BCD so I can play with gearing to suit. They're not all great but I have a stack of different 104's I can try to tweak gearing and chain line before getting a good final rear.

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Oct 01 2015 12:47pm

And even more circles... I could only get this far on the rear cog carrier last night. This part too needs the Swiss cheese diet. Still need to drill holes, but you get the idea the red part has the rear hub spline profile and sandwiches the part I made.
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StinkyGoalieGuy   100 W

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Re: HPC Revolution XXX

Post by StinkyGoalieGuy » Oct 01 2015 12:51pm

Looks amazing. Did you make the red part, or buy it? If you bought it, do you have a link? If you made it, how did you figure out the profile?

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Oct 01 2015 1:01pm

Ebay'd that part. Google "Origin8 Single Speed Converter", I didn't need the gear it came with. Till I get the CNC running I'm limited in my designs. We're between houses right now with our new one delayed, but once I settle in the new place I will have the mill converted back. Version 2.0 of this part will be one piece.

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Oct 01 2015 1:12pm

Now that I look at it a bit closer a dividing plate, rotary table and a broaching setup might be easier. I always thought that spline wasn't symmetrical for some reason?
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kiwiev   10 kW

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Re: HPC Revolution XXX

Post by kiwiev » Oct 02 2015 5:14am

Leeleeducati wrote:Now that I look at it a bit closer a dividing plate, rotary table and a broaching setup might be easier. I always thought that spline wasn't symmetrical for some reason?
So Lee this is for the rear Cog?

Cheers Kiwi

Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Oct 02 2015 5:30am

Correct, rear cog carrier that uses standard 104 BCD front chain rings to give some flexibility in gearing. Here it is complete.
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Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Oct 03 2015 8:02am

Got the 30T so I finalized the front chainring carrier. You can see in the one pic the 30T's have a 2mm step to move them away from the crank arm for clearance. I also made a small 1mm recess for added chain clearance. I guess since the 30T's are designed for single speed use, they are threaded for chainring bolts to go through the crank spider and hold them in place from the front. I'll use these threads to mount both chainrings with bolts through the back. Also with the new narrow/wide tooth profile there's minimal chain movement side to side, I could have probably got away with the rings closer together but some clearance is still good.
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Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Oct 03 2015 10:20am

Here's a few more pics with the crank assy. on the bike. Everything lines up according to plan. Soon it will be time to make the incisions in the frame to pass the chain through. I have some ideas but need to finalize them for the chain tensioner. Might even mill some Delrin grommets and use the frame as a guide? I am a bit limited with rear chainring selection. Even at 30T in the front there's a limit to rear cog size. Hopefully this motor will be strong enough to pull a higher gear.
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Leeleeducati   100 W

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Re: HPC Revolution XXX

Post by Leeleeducati » Oct 09 2015 7:01am

Got back from some work travels so I'll have a bit more time to work on things. Just received the production panels from HPC, world class service from those guys! The pictures don't do them justice but it's like looking in a mirror.
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