BE-Bike - The project starts NOW - Turnigy 130KV Brushless

[Byte]

Hi Guys!

A few months ago I made a topic about converting my mountainbike to electric, I got very helpful reply's from members of this forum (thank you! especially: Aussiejester, Thud and sona1111). Today I turned 17, and I finally bought some stuff at Hobbycity for my MTB. (I actually bought a present for myself lol) The MTB I'll convert is a little old and rusty, but I think it will be OK. Some old pics of this rusty thing (I'll disassemble all the parts, clean etc. them and then re-build the bike before I'll convert it):

Now to the things I just bought at Hobbycity (a total of $480 ):
- Turnigy 80-100-B 130Kv Brushless Outrunner (I know, overkill )
- 2* ZIPPY Flightmax 5000mAh 5S1P 30C
- iCharger 3010B 1000W 10s Balance/Charger I'm very curious about how this thing will perform, at this moment I've got a cheapo 50Watt charger :lol:
- Turnigy Servo tester
- Turnigy HV UBEC (8-42V)
- Some small things like connectors, ball bearings, thread locker and some other things for my other hobby (RC-cars).

Things I still have to buy:
- Castle Creations ICE HV 120A ESC
- Gears, shafts, aluminium, caps etc.

I'll only use 2* 5Ah 5S 30C LiPo's in series, but gear the bike down to about 35MPH to get the current down. As reduction unit I'll try to make something like Mud2005 has:
http://www.endless-sphere.com/forums/download/file.php?id=31041, a belt driven system from motor to a shaft, then a chain driven system on the other side of the shaft.
3 questions about this:
- Where to get a hardened shaft?
- Where to get the 'belt drive system'; a small 12mm inside dia. gear, a big gear and a belt? (Sorry my English isn't that good, I don't know the name of the parts)
- Where to get a freewheel + sprocket that will fit the hardened shaft?
I'm still not sure how the sprocket/freewheel on the shaft will drive the rest of the bike as I want to be able to paddle too.



I'll keep you guys updated...


Oh, and for you who want to know why I'm calling it the BE-Bike: as you see I bought the first things on my birthday, so it's a Birthday Electric Bike :lol: I know that doesn't makes sense lol

 

[AussieJester]

3 questions about this:
- Where to get a hardened shaft?
- Where to get the 'belt drive system'; a small 12mm inside dia. gear, a big gear and a belt? (Sorry my English isn't that good, I don't know the name of the parts)
- Where to get a freewheel + sprocket that will fit the hardened shaft?
I'm still not sure how the sprocket/freewheel on the shaft will drive the rest of the bike as I want to be able to paddle too.

Recumpence could help you with most if ont all of those
items, the item you need for the freewheel is an adapter
I actually just received one from Recumpence myself last week.

I also have some old pulleys from my Turnigy motor i wont be using again
what size tooth count are you chasing ill see if i have one you can have for cost
of postage.

KiM

 

[liveforphysics]

Your going to want to go with the ICE160 at the bare minimum. Going to want about 4x the battery as well

 

[ITgreybeard]

...and if you haven't read Kepler's friction drive story, it could be very worth your while: http://endless-sphere.com/forums/viewtopic.php?f=28&t=16550.

Best wishes.

 

[EVTodd]

...and if you haven't read Kepler's friction drive story, it could be very worth your while: http://endless-sphere.com/forums/viewtopic.php?f=28&t=16550.

Best wishes.

I'm just picturing using a Turnigy 80-100-B as a friction roller. :lol: It wouldn't be quite as compact as Kepler's drive.

 

[Byte]

3 questions about this:
- Where to get a hardened shaft?
- Where to get the 'belt drive system'; a small 12mm inside dia. gear, a big gear and a belt? (Sorry my English isn't that good, I don't know the name of the parts)
- Where to get a freewheel + sprocket that will fit the hardened shaft?
I'm still not sure how the sprocket/freewheel on the shaft will drive the rest of the bike as I want to be able to paddle too.

Recumpence could help you with most if ont all of those
items, the item you need for the freewheel is an adapter
I actually just received one from Recumpence myself last week.

I also have some old pulleys from my Turnigy motor i wont be using again
what size tooth count are you chasing ill see if i have one you can have for cost
of postage.

KiM

Thank you for your reply Kim, I'll send Recumpence a PM.

Thank you for your offer, but then I'll need the right belt + other pulley (the bigger one which will go on the shaft) right? I assume there are some differ; difference in space between the teeth, the width of the pulley right? I would really like to buy them for you, but it would be useless if I can't find the matching belt and pulley. Do you have any idea where I can buy those parts? (Sorry my English is rubbish, I hope you understand )

Your going to want to go with the ICE160 at the bare minimum. Going to want about 4x the battery as well

Hmm... I think I'll order the ICE160 ESC then, although I've seen many powerful E-Bikes driving with a Phoenix 110 ESC? I know my battery's are a bit less for my application so I will try to gear very low and I will also measure how much the Voltage drops under load, if it drops too much I'll order some extra LiPo's.

 

[AussieJester]

The pulleys used in the reduction drives are all 5mm pitch pulleys/belts mate...
Not sure where Recumpence gets his but i purchased all the belts & pulleys i have used here Look under the Pulleys section for what your after, either GT2 or HTD belts are whats you need. Belts are 15mm wide variety.

Best of luck...

KiM

p.s OH...you will definitely need at least 2 more packs too IMHO. I run 6 myself now used to have 8
no difference in sag but obviously range would be less, i have no need for more than 10km rides so not probs for my application.

 

[Byte]

The pulleys used in the reduction drives are all 5mm pitch pulleys/belts mate...
Not sure where Recumpence gets his but i purchased all the belts & pulleys i have used here Look under the Pulleys section for what your after, either GT2 or HTD belts are whats you need. Belts are 15mm wide variety.

Best of luck...

KiM

p.s OH...you will definitely need at least 2 more packs too IMHO. I run 6 myself now used to have 8
no difference in sag but obviously range would be less, i have no need for more than 10km rides so not probs for my application.

Kim,

MANY thanks for that link! That's an awesome site with LOTS of stuff I will search for some HTD/GT2 pulley's right after posting this.

Ok ok... you guys convinced me I'll order 2 extra LiPo's a.s.a.p.!

 

[Byte]

I've searched a bit at sdp and got a problem... I need a pulley as small as possible but the smallest pulley with a 5mm pitch, GT2/HTD and 12mm bore has got 28 teeth, the biggest 72. This would only be a ratio of 2.57, so the second reduction should be HUGE (which is almost impossible/too much work) OR I need to buy a HTD pulley with a 5mm pitch which has a 8mm bore and 17 teeth (this would be a ratio of 4.24 if used with a 72 teeth pulley) and then drill it to a bore of 12mm. What do you guys think?

@Kim: would'nt a GT2 2/3mm pitch work also? Or do these break easier or something like that???

 

[Miles]

You could bore out a 17t 5M PowerGrip pulley but, you'd then need to drill and tap between the teeth, to fix it. Forget 3M :wink:

 

[AussieJester]

I have 18 and 22teeth 5mm pitch pulleys here with 12mm bore. (18 tooth came standard from Recumpence on the drive unit)
Both though have now been snapped up since you said you wouldnt be able to use
them in your earlier post another member asked yesterday if he could have them
they were posted this morning sorry. Gotta be quick around he buddy haha...Just
bore them out though no probs there, if you go with the smaller tooth
you will need to do as Miles has explained in above post, the 18 tooth
sprocket i have here has to grub screws between the teeth.

KiM

 

[Byte]

You could bore out a 17t 5M PowerGrip pulley but, you'd then need to drill and tap between the teeth, to fix it. Forget 3M :wink:

Hmm.... I think that won't succeed me lol

I have 18 and 22teeth 5mm pitch pulleys here with 12mm bore. (18 tooth came standard from Recumpence on the drive unit)
Both though have now been snapped up since you said you wouldnt be able to use
them in your earlier post another member asked yesterday if he could have them
they were posted this morning sorry. Gotta be quick around he buddy haha...Just
bore them out though no probs there, if you go with the smaller tooth
you will need to do as Miles has explained in above post, the 18 tooth
sprocket i have here has to grub screws between the teeth.

KiM

No problem, I'll ask Recumpence if he wants to sell me a 18t 5mm pitch pulley

 

[AussieJester]

No problem, I'll ask Recumpence if he wants to sell me a 18t 5mm pitch pulley

i got mine from the link i gave you ...

KiM

 

[Byte]

No problem, I'll ask Recumpence if he wants to sell me a 18t 5mm pitch pulley

i got mine from the link i gave you ...

KiM

With 12mm bore??? Am I blind?

They only got 4, 5, 6, 8 and 14mm bore 18t pulleys, no 12mm bore? Pic:

 

[AussieJester]

LOL mate, you buy the smaller id and drill them out you will be doing alot more than drilling a pulleye to fit a rc motor to a bike if this is a problem the rest of the work you need to do is going to be a struggle..

KiM

 

[Byte]

LOL mate, you buy the smaller id and drill them out you will be doing alot more than drilling a pulleye to fit a rc motor to a bike if this is a problem the rest of the work you need to do is going to be a struggle..

KiM

I thought you ment to buy a 12mm bore pulley.. sorry

I think you're right lol, I'll buy one with a smaller bore and TRY to drill & tap between the teeth Well, it's probably not that I can't do it, but I'm too lazy I think lol. Since a month I finished a RC conversion, all the parts I made were made with some files, a dremel and some other little cheap tools. It took me SO damn long to finish all these parts that I don't want to do this all again for my bike heheh
This were some of the parts btw, which imo were pretty nicely made for the tools I had: http://i424.photobucket.com/albums/pp328/Patrickbottcher/Losi LST Project/LST1dot5/IMG_2649.jpg

 

[AussieJester]

Yup good job buddy don't need fancy tools to get pro results if you have a lil skill and are patient

Drilling the pulley out is piss easy you wont have any probs.

KiM

 

[Byte]

Update!


Today I FINALLY (it took 1,5 month....) got my HC package! Some pics of the items from the HC package and some other ones I got a few days before:

ENO 16T Freewheel

Paint! Correct: the bike will be Black, Green and Pink!

Adapter for the ENO freewheel with 1/2" bore from Matt

The awesome package that came today from HC! 1000Watt charger, 2* 5S LiPo's, 8mm Bullet connectors, UBEC, Servo tester and the...... MEGAHUGEMEGAMONSTER Motor! This motor is sooooooooooooooo huge, big and heavy! Totally awesome!

My sexy hand + XXXXXL motor


And I also ordered 2 extra 5S LiPo's a few weeks ago, this package is at the customs right now

 

[drewjet]

Looks to be an interesting build.

Have you figured out your reduction method yet?

I would suggest staying away from the 5 mm Belt, It will NOT stand up to the abuse these motors can put out.

 

[AussieJester]

Great to see you got a delivery of 'goods' drewjet is correct on the 5mm belts when used on smaller diameter pulleys, final
drive belt on my cruiser worked fine though, only changed it as i wanted lil more top end speed.

KiM

 

[Byte]

Looks to be an interesting build.

Have you figured out your reduction method yet?

I would suggest staying away from the 5 mm Belt, It will NOT stand up to the abuse these motors can put out.

Well, my choice was actually to use a 5mm belt The first pulley would be 13T and the second one 72T, and I would try to get them as far as I can from each other so the more teeth grip on the pulley. (Sorry, I can't explain this well, I hope you know what I'm trying to say)

What would you recommend? Chain? Gears?

Great to see you got a delivery of 'goods' drewjet is correct on the 5mm belts when used on smaller diameter pulleys, final
drive belt on my cruiser worked fine though, only changed it as i wanted lil more top end speed.

KiM

Hi Kim

How much teeth do your pulleys have on the cruiser? I've seen a few people who use the 5mm belts on this forum (with the same motor) without having any issues, so I thought it would be good enough for my bike too.

 

[Miles]

If you want to use synchronous belts you need to give some attention to the specification, that's all.......

http://www.endless-sphere.com/forums/viewtopic.php?p=126539#p126539

 

[drewjet]

I had a 22 tooth on the small pulley and 72 on the large as received from Recumpence. It worked fine until I went to about 5000 watts. If you are going to drive it like a commuter, no problem. If you want to extract maximum power NO way. especially with only 13 teeth. Go to either #25 or 219 chain. #25 has held up well, though I did wear out a sprocket on mine in about 200 miles. Ideally I think It will take 219 to solve that issue. Now please note that my bike sees severe off-road condition, sand mud water, and I did NOT do proper chain cleaning after ( I am trying to be better about this now)

 

[Byte]

@Miles: thank you for the link, but after reading what drewjet said I think I will go with chain drive.

@Drewjet: I DEFINITELY want to get the most power of it I've searched a bit at sdp-si and found a #25 72T sprocket, which has a 1/2" bore, so that would be a direct fit. (https://sdp-si.com/eStore/PartDetail.asp?Opener=Group&PartID=50214&GroupID=585) I also saw a #25 14T sprocket, which has a 0.25" bore, this would be too small (I need a 12mm bore) but I could drill it out to a 12mm bore. The only problem which I can think is that the set screw will come loose as it will only be screwed in 4mm.

I made a thingy in paint to make it a bit clearer:

The black "hole" is the 12mm bore which I would drill in.

Do you think 4mm will be enough?

 

[drewjet]

12mm are tough, there isn't much out there. I have an Astro and it's 3/8, plenty of choices for me...sorry

You could get the shaft turned down