Recent content by orion4096

I haven't been riding my ebike much lately, but I did take it out 5 times a week for several months after the fix with no issues. It still gets used 1-2 times a month. I may be riding it more regularly again if my job relocates.

I had a half-width gear (to avoid using the mill which cost almost 3x) made out of 7075 aluminum. It arrived late this week and I drilled some tapered holes and bolted it on. Works great. I'm looking forward to riding it to work next week. If I was in the market for a new bike I would...

I received the hub adapter from emachineshop. It's machined well and looks like it was done using a waterjet or laser. Unfortunately, my measurements were a little on the loose side so it's not a press fit. I used some JB weld to bond it to the hub and bolted up a nylon and PLA gear this...

I still need to radius the edges, but here's what I came up with. The inner adapter is being made out of 0.25" aluminum sheet metal with 6 threaded holes for a printed gear to bolt into. There's no convenient way to machine (waterjet?) the part myself so I'm trying emachineshop.com. It's not...

Here's what I came up as test fit for the inner and outer splined surfaces of the gear. I'm tempted to super glue the two pieces together and bolt it together this weekend. Would be interesting to see how long it lasts and what breaks. Long term, I need to figure out a better method than glue...

I PM'ed as19 (in very poorly written German) about his new hub and gear, but haven't heard anything back, yet. There's also a post in that thread from earlier this year which says he probably isn't making them anymore. I used a little force and was able to get the gear off the hub. Then...

Thanks for the suggestions. I called the hotline number: - No known spares or service available for classic motor in US. The classic was never sold in the US. - The person confirmed that a shop close to me is a certified bosch ebike dealer/repair place, but didn't think they would be able to...

I contacted a few different ebike shops with no success. Looks like this is going to turn into a project. It shouldn't be too hard to 3d print a new one. I doubt a PLA version will be very durable, but once I have a working replacement part I can find someone to CNC one out of aluminum.

My bosch classic mid-drive ebike started making a rattling noise at the end of last week. This morning I got on the bike to go to work and the pedals locked up. I opened it up and found a broken plastic gear. Some youtube videos suggest it's easy enough to pull the crank out and remove the...