Electric "tough bike"

Show off your E-Scooter or Motorcycle creation here.
vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Electric "tough bike"

Post by vax » Mar 11 2012 1:08pm

Hello again. This is my 6th build so far, and it started in Solidworks.
The idea is pretty much same as for Stealth Bikes - rugged aluminium monocock, maximum shock travel.
However, I'm using 20'' BMX wheels to lower centre of gravity and enhanche agility.
So far I have 3 components waiting - Velectris Phantom hub motor, Kelly KBS48051 controller (48V, 20A) and Marzocchi 888RV fork.
Rear shock will be from CZ motocross bike, pressure air type, it's really light and has great adjustability.
Batteries will be ThunderSky 48V 20Ah LiFePO4, which should arrive soon.
Image
Image
Image
Image
Image
Prototype fabrication https://www.facebook.com/3dflux

User avatar
rojitor   10 kW

10 kW
Posts: 955
Joined: Mar 23 2011 6:39pm
Location: vigo spain

Re: Electric "tough bike"

Post by rojitor » Mar 12 2012 8:08am

Right now at solidworks looks just great, i like that bomber style. Will 48v be enough? Haha i got addicted to 72v :)

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » May 16 2012 2:27pm

Some updates:
The battery is still on the way, latest promise is 20. of June.
The BMS has arrived, it's made here in Estonia by company called "DriveCord". It's modular, consisting of slave boards and master board and can be used in various battery systems. Actually it's also used in some electric cars and so far works great.
http://www.zev.ee/files/uploads/LiYFePO2.jpg
http://www.zev.ee/files/uploads/L2e_pic6.jpg
I'm still waitng of custom made stainless spokes from Czechs republic, it's been over a month now...
However, the front end is at my table, and I really like the look :D [already did some eyeballing sessions]
Image
Prototype fabrication https://www.facebook.com/3dflux

Hillhater   100 GW

100 GW
Posts: 9249
Joined: Aug 03 2010 10:33pm
Location: Sydney ..(Hilly part !) .. Australia/ Down under !

Re: Electric "tough bike"

Post by Hillhater » May 17 2012 3:03am

Seems too nice to be limited by a 48v, 20A controller ? :o
This forum owes its existence to Justin of ebikes.ca

miuan   10 kW

10 kW
Posts: 984
Joined: Nov 26 2009 4:16am
Location: Slovakia

Re: Electric "tough bike"

Post by miuan » May 17 2012 4:00am

vax wrote:I'm still waitng of custom made stainless spokes from Czechs republic, it's been over a month now...
Did you order at Šroubárna Marek? They are not the fastest. What rims and spoke guage are you using?

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » May 17 2012 10:51am

miuan wrote:
vax wrote:I'm still waitng of custom made stainless spokes from Czechs republic, it's been over a month now...
Did you order at Šroubárna Marek? They are not the fastest. What rims and spoke guage are you using?
Don't know exact manufacturer, I ordered them from local motorcycle shop. 2mm diameter, 128mm length and I'be using same rim as in front, that is 20'' BMX...
The guy at bicycle shop said X1 pattern is possible. I hope he's right.
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » May 17 2012 10:53am

Hillhater wrote:Seems too nice to be limited by a 48v, 20A controller ? :o
It's a start. I don't have too much financial resources right now, so it have to be enough. The batteries and BMS alone are quite expensive.
Also, the motor I have (Velectris Phantom) is labeled as 250W.
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Jun 08 2012 4:03pm

Finally, spokes arrived, but someone had made a mistake, there's 30 (+3 spare) spokes instead of 36.
I lied previously, didn't remember correctly - those are 3mm stainless spokes, very nice and strong.
I had to enlarge the holes to 6mm on the rim, and to drill at angle for correct spoke placement.
The spoke pattern is 2+1, because I messed up with calculations and spokes were too long for X1
But here it is:
Image
Sorry my english...
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Aug 23 2012 2:40pm

My Extra 3 spokes arrived from Taiwan... At last. However, I had a deal with local EV company for battery delivery, and it's also dragging behind. So, still no sign of batteries (they gave me BMS boards though).
Today I made new, simpler version of my frame - now it's pretty much just two 5mm aluminium sheets, that are held together by battery box, steering column and suspension axle. I really like it this time, it's so minimalistic and easy to fabricate. All the good things must be simple :D It's missing a saddle post and rear spring/shock right now, because I ran out of clear ideas. Maybe tomorrow, with large cup of strong coffee :D
Image
Prototype fabrication https://www.facebook.com/3dflux

buzzfirst   10 W

10 W
Posts: 72
Joined: Nov 20 2008 1:00pm

Re: Electric "tough bike"

Post by buzzfirst » Aug 23 2012 8:51pm

I like this frame a lot. It looks like it could be built by far more people than a tube frame. Cad layout of the frame sides and a few :) more details looks doable. Keep at it for all us non tube welding guys.

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Sep 03 2012 2:30pm

Today's progress. Still minor bug fixes to do, but overall it's nearly complete.
Rear shock will be CZ motocross air shock (from 70-s). Easy to adjust height with air pressure.
Image
Image
Image
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Sep 13 2012 2:18pm

Some bug fixes: smaller cutaway sections in the frame; battery covers added (GRP or carbon)
Image
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Feb 19 2013 11:04am

Time has seriously passed, but project hasn't stopped. Just delayed by battery deal.
Today, however, my batteries arrived at last.
I didn't want to make any frame construction before batteries lie on my desk. So I made cardboard mockup:
Image
Image
Image
Image
Image
Prototype fabrication https://www.facebook.com/3dflux

User avatar
spinningmagnets   100 GW

100 GW
Posts: 10652
Joined: Dec 21 2007 10:27pm
Location: Ft Riley, NE Kansas

Re: Electric "tough bike"

Post by spinningmagnets » Feb 19 2013 2:49pm

Ahhhhh!...Cardboard-Aided-Design (CAD), one of my favorite techniques! Looks great, and even if I wanted a different frame style for myself, builds like this will document clever DIY methods that are very useful to the group.

User avatar
jpgey   1 kW

1 kW
Posts: 499
Joined: Jan 12 2012 7:16am
Location: France

Re: Electric "tough bike"

Post by jpgey » Feb 19 2013 3:43pm

vax wrote:Time has seriously passed, but project hasn't stopped. Just delayed by battery deal.
Today, however, my batteries arrived at last.
Nice to see an ebike with this kind of battery :)

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Mar 21 2013 3:11pm

News again. Aluminium pieces arrived from laser cutting and I spent two hours trying to produce exact bends. First ones were a bit overshoot, but those were fixed by rubber mallet beating.
Most of the bends are 10 degrees, except for saddle carrier, which has 8 degrees incline.
I thin I make all the files freely availavble to anyone once it's complete.
Image
Prototype fabrication https://www.facebook.com/3dflux

User avatar
pendragon8000   1 MW

1 MW
Posts: 1740
Joined: Sep 28 2012 3:29am
Location: Adelaide, Australia

Re: Electric "tough bike"

Post by pendragon8000 » Apr 04 2013 9:14pm

Cool design. Like a stealth bmx ...? Looks like it won't weigh too much.
Have you done any welding yet?
8)HYENA high power ebike kits
My builds
scott 29er + Hyena kit, mon-goose to MON-STER 6KW, Free Agent RC Mid Drive, videos

my bike goes so fast 'cos it charges the battery while I pedal

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Apr 10 2013 2:36pm

Received my 48V 5A charger from Ping. Seems decent construction.
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Jun 06 2013 1:56pm

The frame is going to welder next week (at least I hope), so I'm prepping all the pieces and drawings.
Bought rear suspension bearings, cheap ones, for welding - outer bushings are welded to sheet aluminium around and those pieces are centered by shaft and bearings.
Image
Image
Image
Prototype fabrication https://www.facebook.com/3dflux

User avatar
pendragon8000   1 MW

1 MW
Posts: 1740
Joined: Sep 28 2012 3:29am
Location: Adelaide, Australia

Re: Electric "tough bike"

Post by pendragon8000 » Jun 07 2013 5:44am

3d triangles.JPG
3d triangles.JPG (74.86 KiB) Viewed 12883 times
I think you should triangulate in 3 dimensions. I just put a few lines there to show what im thinking.
I mainly was motivated to post this because i have had my last build frame warp and almost snap after many moderate jumps, 200 or so Kms..
its now solid as with some 3d triangles.
edit
sorry if that was a semi constructed photo...
8)HYENA high power ebike kits
My builds
scott 29er + Hyena kit, mon-goose to MON-STER 6KW, Free Agent RC Mid Drive, videos

my bike goes so fast 'cos it charges the battery while I pedal

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Jun 07 2013 6:10am

Yes there's some details missing at the photos. See 3D renderings for reference.
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Jun 09 2013 5:08am

Some new pictures:
- steering column
Image

- last minute reinforcements
Image

- saddle post diagonals
Image

- rear shock
Image

- rear suspension assembly
Image
Image
Image
Prototype fabrication https://www.facebook.com/3dflux

User avatar
jansevr   1 kW

1 kW
Posts: 470
Joined: May 27 2011 6:58pm
Location: Milwaukee, WI, U.S.

Re: Electric "tough bike"

Post by jansevr » Jun 10 2013 10:14am

very cool project!

xadmx   1 kW

1 kW
Posts: 332
Joined: Feb 18 2013 8:17pm
Location: uk

Re: Electric "tough bike"

Post by xadmx » Jun 10 2013 10:32am

pendragon8000 wrote:
3d triangles.JPG
I think you should triangulate in 3 dimensions. I just put a few lines there to show what im thinking.
I mainly was motivated to post this because i have had my last build frame warp and almost snap after many moderate jumps, 200 or so Kms..
its now solid as with some 3d triangles.
edit
sorry if that was a semi constructed photo...
Is the rear swing arm made from 5mm it looks like its going to twist side to side to me. Clamp a wheel or block in the rear drop outs and see if you can bend the wheel side to side.
Adam

User avatar
Willow   10 kW

10 kW
Posts: 797
Joined: Sep 06 2011 7:42pm
Location: Tasmania

Re: Electric "tough bike"

Post by Willow » Jun 23 2013 8:22pm

...I have similar concerns at the 'V' in the side plates near the neck. There is potential for a lot of sideways deflection, and also potential for cracking at the corner of the 'v' - aluminium fatigue can be very serious - especially at high stress points. The neck will exhibit extremely high stress loading under normal conditions.... good luck with the build - it's looking good.

Post Reply