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  1. shenzhen_ex

    DH 2WD: Seeking Design Reviews

    So you think my bike won't stay up with a kick stand! Darn, i did't think of that. HEY, Maybe i can make a kickstand arm that swings down from my controller housing that offers a stable 3rd point. You got me thinking about the reason for my controller housing concept. The reason is stealth and...
  2. shenzhen_ex

    DH 2WD: Seeking Design Reviews

    I have all the purchase parts for my planned DH 2WD except the battery and spokes. In the pictures below you can see that I have made the following designs: 1) Front hub motor axle adapters and TA: I will cut the axles and use 20mm adapters, one connected to a TA. Adapter components are 420...
  3. shenzhen_ex

    DH Rear Hub Motor Custom Adapter:

    Dogman, I am hoping that the axle extension allow it to span the dropout width? Yes. It is 150mm width. Thanks to this forum I have a plan to make the forks work. I have dirt cheap or free access to CNC mill / lathe so i was actually looking forward to this fabrication challenge.
  4. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    I want to install a plug and then use fat wires to the controller. Can i just use one big multi-pin plug for the entire connection controller-to-motor?
  5. shenzhen_ex

    DH Rear Hub Motor Custom Adapter:

    My rear hub motor is designed for a smaller dropout width. My axle is too short to bolt up on the disk side. The problem: Is this a valid solution? I will need to cut some of the axle off of the disk side to make this work. I love these dropouts :wink:
  6. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    NO WAY MAN!! I am cutting my axles. I will have 12-15 mm per side in the adapter and the adapter will be made of pre-hardened tool steel. The way i see it when you bolt up a hub motor in a steel fork you are not catching more than 12 mm of the axle anyways.
  7. shenzhen_ex

    Forks 500w front hub conversion mine snapped

    I have a concept (thanks to this forum) that i plan to fabricate that will adapt the hub to the fork.
  8. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    i will not be running regen, so i think 1 torque arm on the non-disk side is enough. BLUE and GREEN=Aluminum ORANGE= P20 Steel Wire protection not yet modeled
  9. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    I don't understand the "large flat head" option. I believe the adapters needs to be installed from outboard of the dropout so anything larger than the 20mm dia will not fit. the adapter can't be installed from inside the fork because then the hub axles won't fit. I like your initial suggestion...
  10. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    :o The torque arm does not engage with the flats on the axle? Instead it clamps to the 20mm OD adapter? I did not get that at first. Since the adapter needs to slip in from the outside,the torque arm engagement features will have to remove steel. Since there is only 12 mm of axle length in the...
  11. shenzhen_ex

    Forks 500w front hub conversion mine snapped

    Torque arms? I don't think there is enough room for a TA on the disk side on my fork. Is the second torque arm helpful, why?
  12. shenzhen_ex

    Forks 500w front hub conversion mine snapped

    My forks are Zoom, but they are not steel :| They are on the website you listed. They look strong, what do you think? I am building a 2WD w/ a 500W motor up front as well.
  13. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    Thanks for the constructive criticism, I probably over engineer everything i design. With your help, and that from John in CR, here is what i have come up with: - Cut the axles leaving 12mm per side (still working on how to keep from cutting the wires in the process). - Fabricate 20mm O.D...
  14. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    I like that idea. That will leave 10-12 mm on each side. How can I cut the axle without damaging the wires? I already spent an hour in this forum looking for an answer, i'm sure it is in here somewhere.
  15. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    I really need long travel forks to go with my 220mm travel frame, so "normal" forks were not considered. Here in China, resale value for an e-bike does not enter into the build planning.
  16. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    I already have my forks. They have a cross brace so i can't separate the 2 fork stanchions. In the image below you can see the cross brace. Currently my dropouts only have a 2mm opening from the bottom (see image below). To do what you recommend with the axle adapters i would need to widen...
  17. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    I will have a motor in the back as well. That will also require custom adapters. I am going to break the fabrication up into 4 steps. (1) front hub adapters. (2) rear hub adapters. (3) controllers mounting (4) battery mounting. Below are my 2 motors: 48V 500W each
  18. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    WOW! My first reply. Thanks! I am building a 2wd. The clamps i am planning to use should be stronger than the ones in the model: I was hoping that the green bracket alone would prevent rotation, and purple arms would be for added measure. I won't be doing any DH, but curbs will be jumped.
  19. shenzhen_ex

    DH Fork Hub Motor Custom Adapter: Safe?

    This is my first e bike build. I need to fabricate adapters for my DH forks to accept a hub motor. Is this Safe? From the workshop of the world, a CNC shop on every corner and eBike city!
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