9C Hub (Rusted Solid)

[methods]

.
.
I have been pounding on this roached 9C for half an hour. It is an original from back in the day, bought it from Justin.
.



Back then they were polished Aluminum. Fast motor intended for a 20" tire. After serving many years on many bikes, it sat in the woods for 4.2 years and turned powder white. After that it sat (in the bushes) and rolled (here and there) for another 4.2 years, and as it stands, it is soaked in penetrating fluid.

At one point, a few years ago, I did get it turning (it was frozen then) and fitted it to the rear of my Trike (it is a Front motor, 12mm axle). This was the trike that had its legs spread for the original CroMotor, another story all together... but it fit.



The damn motor wont budge now. . . so I drilled a hole in the side and sprayed an overwhelming quantity of Blaster in there.



In other news, the Anderson Connectors lasted over a decade with no indication of UV degradation. Wish I could say the same about the Deutsch. Technically it is NOT a Deutsch, but an Amphenol A-Series knock-off... but either way it is clearly showing "crusting" and it is not in any way oblivious to the UV.

For now I will blame Amphenol, until I can repeat the test with a legit DT.

-methods

 

[amberwolf]

If it helps:
Kingfish's "RUST: DIY Hub Motor Repair & Restoration" thread:
https://endless-sphere.com/forums/viewtopic.php?f=30&t=34135

 

[methods]

Rad thread, thanks!

Another member secured a really nice 12S 16Ah pack for tomorrow, so I am highly motivated to get this motor and controller back to confirmed-working.

The damn hollow 12mm shafts are so small and soft that they are spinning inside of my torque arms. I had FIVE torque arms on the back (to fill the gap on the very wide drops) and all of them spun out (sigh). I am going to revert to the old field fix of hose-clamping a pair of 3/4" wrenches on the nuts to get the bike done in time for the ride.

(The only time I build an ebike these days is when I need one on 24hrs notice)

-methods

 

[amberwolf]

If it helps, on one of the 9C type motors I tried and broke the hollow axle on, I welded a (broken) wrench to the axle on the side opposite where the phase wires go into the axle, just outboard of the cover and bearing, with that side of the motor assembled. I'm sure it wasn't good for the bearing, and I had ice to stick on the axle at the wiring hollow section as I did it. But it didn't spin out anymore, until it just sheared the axle off just inside the bearing face.

If I had the ability, I'd make a whole new stator support for all of my motors that included a mount for a large-diameter pipe axle like Farfle did on his dual-stator MP motor build. Then modify existing or make new covers for the larger-ID bearings that would require. Hollow or not, I wouldn't be having broken axle problems with THAT, even on the SB Cruiser trike with 350lbs of stuff (or dogs) in the back.

Not sure how well it would work to allow bicycle freewheels on there, but I could still bolt sprockets and disc rotors to them, and stick a freewheel on a jackshaft someplace.

 

[DogDipstick]

I have a vat of strong Blackstrap Molasses that I sit things into that might get worked on and need... Much better than a penetrant imo.

Much less aggressive than the vat of hot Lye. Sodium Hydroxide would eat that cover in a day, at 50% or more dilute. Lol. Rust would be gone, tho.

Also, about the Tq. arms, have you ever thought about doing diy case hardening? Very easy, very strong. Just a torch and a powder dip. They wont break then. Case hardening takes the best of both qualities of the metal.

 

[serious_sam]

I have been pounding on this roached 9C for half an hour. It is an original from back in the day, bought it from Justin.

If nobody else is going to bring up the elephant in the room, then I will...

Methods, your problem isn't excessive rust, or lack of penetrant. It's a lack of hammers. Only 5 hammers? That's rookie numbers man! :lol:

 

[methods]

I have a vat of strong Blackstrap Molasses that I sit things into that might get worked on and need... Much better than a penetrant imo.

Much less aggressive than the vat of hot Lye. Sodium Hydroxide would eat that cover in a day, at 50% or more dilute. Lol. Rust would be gone, tho.

Also, about the Tq. arms, have you ever thought about doing diy case hardening? Very easy, very strong. Just a torch and a powder dip. They wont break then. Case hardening takes the best of both qualities of the metal.

All valuable ideas - I will pull this back up when the time is right. Thanks!
-methods

 

[methods]

Methods, your problem isn't excessive rust, or lack of penetrant. It's a lack of hammers. Only 5 hammers? That's rookie numbers man! :lol:

No way, there are more outside of the picture.

That is actually my 8yo sons "hammer station". He has a vice,9 hammers, and buckets of nails in every size. That is where he works his magic, tho lately he is more interested in making candles.

... I will admit tho, I am a bit out of practice. For the last month I have been doing heavy work with concrete and rocks. In that arena it turns out "bigger hammer" is just about the only thing that works, except water. I have found that water is extremely useful for breaking up binds of tightly packed rock with dirt. I pickaxed and shoveled more than I would like to admit lately, and I am afraid the "rough touch" followed me to this project.

-methods

 

[serious_sam]

That is actually my 8yo sons "hammer station". He has a vice,9 hammers, and buckets of nails in every size. That is where he works his magic

Hammer station. That's awesome!

 

[methods]

Thanks to the help of a member, phase one of this project got sorted out: "Get the bike rolling under power!"

Works great, put a few miles on it yesterday. My first geared motor.



I was really happy with how light the Motor/Controller/Battery ended up. The controller fits in the palm of your hand, the motor is significantly lighter than the 9C I have here, and the setup ran fine off of a 4Ah 12S pull-down lipo.

... so... yea...
I was going on and on to Kimberly about how I want to go "light" with the builds, and light is so much better, and power to weight, and all that. lol.. yea... that kick lasted exactly 24hrs, then I built this piece of shit



That is my first 13S pack, gonna name it "Lucky 13"

...

Since I am off and running again, another member farther north contacted me with some opportunities ... and... hopefully we will get to chase that down sometime soon.

-methods