Belt drive Sprockets on the Cheap!

1000w, that bike is crunk! No hoopty ride here, that's sick yo!

At least, that's what my students would say. I'll just say that is some *very* clean workmanship!

Excuse me, I have to go read the rest of that thread now.

Miles, way to go on that crazy lantern gear thingy. I don't know if it a winning idea, but it's a heck of an idea regardless.

How it relates to lanterns though...

Katou
 
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:) I was just this morning thinking about the wooden pulley and vinyl electrical tape drive system that I had built when I was a relative youngster. I had an old Batavus moped that I got for $50 and that wouldn't start, and I was tired of pedaling it during the process.

So I turned a wooden pulley out of a piece of maple branch and rounded the surface for belt retention. Then I took a roll of the tape and went around and around between the wooden pulley and the moped flywheel, and presto, a belt of the necessary length. The tape was applied with the roll upside-down, so that the adhesive was on the outside. I wrapped a final layer right-side-up to make the belt nonsticky. Then, I plugged in the 1/4 hp motor and while the motor was spinning away, I played with throttle and choke settings a couple of minutes and the engine caught and started up.

I recalled that memory as I was thinking that I don't want to cut over-sized mounting holes in more of the plastic sprockets that I got cheap from Smallparts, since they no longer distribute them, and I don't want to waste the ones that I still have on hand. So, I may be trying something along the lines of wooden pulleys and unconventional belts. I'm also considering vacuum cleaner belts. Or if I stay with the plastic chain, sprockets made from layers of cereal box-type cardboard treated with super glue. I need low-cost ways at least for trying out ideas without consuming limited part supplies. I might be able get away with something like that because my system is not high power. I aim for cheapness and relative simplicity because I've gotten tired of the fairly bulky, many-component drive that I've been using.
 
Superglue lamination will send you to the poorhouse. Laminate with white glue, very thin layer. Laminate until done, dry in oven, then soak in dilute white glue mix until soaked, then dry again.

I used to do this for making bridges, makes the item pretty tough indeed. Trim with a sharp chisel on a lathe. However, under heat, the glue will start to loosen, it is essentially thermoplastic.

Katou
 
This thread of mine may be interesting to some here.

http://www.endless-sphere.com/forums/viewtopic.php?f=28&t=26418&p=381578#p381578

Cheers,
Matt.P.
 
Has anyone considered using pulley stock and cutting it up into pulleys?

I have found a supplier selling HTD 5mm pitch 6061 pulley stock 200mm wide, so could make around 12 pulleys at 15mm wide (taking into consideration waste from the thickness of a cutting blade) for $360, so $30 a pulley, and did I say this is for a 126 TOOTH pulley!!!7.85" diameter!!

could achieve some great ratios here:

16T-126T - 7.88:1
20T-126T - 6.30:1
25T-126T - 5.00:1

photo-big_pulleys_bar-stock.jpg
 
damonjackson_spl said:
Has anyone considered using pulley stock and cutting it up into pulleys?

I have found a supplier selling HTD 5mm pitch 6061 pulley stock 200mm wide, so could make around 12 pulleys at 15mm wide (taking into consideration waste from the thickness of a cutting blade) for $360, so $30 a pulley, and did I say this is for a 126 TOOTH pulley!!!7.85" diameter!!

could achieve some great ratios here:

16T-126T - 7.88:1
20T-126T - 6.30:1
25T-126T - 5.00:1

quote]

Yes I have just started looking into this as well. I hadn't found a stock this large though. But it is interesting. At this point I think I am looking for something in the 20t and 80t range. But I need to see how large the small gear can be bored before determining the size of the large gear. Beside I think I am going to be limited to only 5" dia on the large gear. Because of this limitation I will likely need to use a double reduction. :(

Can you share where you found the gear stock?

Bob
Click to expand...
 
Well if I could sell 9 x 126t pulleys at $40 each or so I'd buy the pulley stock cut them up. Will need the face machined to exactly 15mm or 20mm.

I found them here http://hneuman.com/pulley-stock-c-22.html
 
Miles said:
SDP SI also sell 5M GT or HTD pulley stock.

https://sdp-si.com/eStore/Direct.asp?GroupID=345
Click to expand...

$537 for 150mm useable length so 9 pulleys at $60 per pulley.

H NEUMAN still looks like better value!!
 
boostjuice said:
Hillhater said:
. :shock: .. OK, a prize for the first to build a completely wooden drive train on their Ebike ! ? :lol:
Click to expand...

:mrgreen:
marco-facciola-5.jpg
Click to expand...

That freewheel is something like I could use to place a large rear sprocket on a standard 10 speed wheel but on a freewheel instead of fixed. I would first need a solid fixed mount on the hub portion between the spokes that would extend out through the spokes, and the freewheel would mount to it. This type of freewheel might best be made of plastic.

The operating freewheel mechanism must be several inches in diameter and then the sprocket even wider as it mounts to the freewheel. The freewheel mounts to the solid mount that screw or bolt clamps onto that inner portion of the hub that I mentioned. That inner mount onto the hub between the two sets of spokes must grip with a ton of static friction to prevent slippage that would damage the spokes as the assembly would otherwise want to rotate into them and put force on them. Yet, don't want so much force as to crush the hub.

Thanks for the memory-recalling image, Boostjuice.
 
I found this one on ebay, looks like it could be a runner for purpose, I bought a twin disc front wheel hub from the guy recently and that was well made and shipped promptly......

$135 for front and rear with a 1.37" thread sound like a steal.

http://cgi.ebay.com/Belt-Drive-Sprocket-Front-Rear-Set-NEW-Single-Speed-/250786920469?pt=Cycling_Parts_Accessories&hash=item3a6410b815
 
comradegerry said:
I found this one on ebay, looks like it could be a runner for purpose, I bought a twin disc front wheel hub from the guy recently and that was well made and shipped promptly......

$135 for front and rear with a 1.37" thread sound like a steal.

http://cgi.ebay.com/Belt-Drive-Sprocket-Front-Rear-Set-NEW-Single-Speed-/250786920469?pt=Cycling_Parts_Accessories&hash=item3a6410b815
Click to expand...

That is FANTASTIC value!!

Great find!!!

Thanks for sharing.
 
I emailed the seller with regards to if he had any more of ebay item no 250786920469 which sold for $135 and he informed me had additional units. Price crept up to $150 as a buy it now option, when he relists the item. I am going to pick one up to test the quality, I will open the freewheel and let you guys know what they are using inside. I am planning to limit my power to around 750watts so an all belt tranmission should hold up, hopefully.
 
Hey what would the smallest lightest belt/pulley setup be that would handle around 3500 watts as the primary drive off the motor? I would need to be able to get at least VERYclose to 5:1 reduction from it. Anybody know of anything reasonably priced for a lighter power level like this? I figure there has to be something like this out there, I am having problems with my primary chain wearing out tensioner rollers now... I got about 60 or so miles out of it and at $12.00 a piece, its worth it to find a solution. Plus it would be much quieter and smoother!
 
Whiplash said:
Hey what would the smallest lightest belt/pulley setup be that would handle around 3500 watts as the primary drive off the motor? I would need to be able to get at least VERYclose to 5:1 reduction from it. Anybody know of anything reasonably priced for a lighter power level like this? I figure there has to be something like this out there, I am having problems with my primary chain wearing out tensioner rollers now... I got about 60 or so miles out of it and at $12.00 a piece, its worth it to find a solution. Plus it would be much quieter and smoother!
Click to expand...

I'd love to know the answer to that one too. But do you really consider 3500w as a "light power level"? I'm only looking to run 2000w and I consider it as a resonable size motor. What RPMs is your motor pulling at full power? Bob
 
Whiplash said:
Hey what would the smallest lightest belt/pulley setup be that would handle around 3500 watts as the primary drive off the motor?
Click to expand...
You need both torque and rpm in order to specify a belt drive system.

See the tables in the attached pdf for a general idea of the capacities of HTD.
 

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dumbass said:
Whiplash said:
Hey what would the smallest lightest belt/pulley setup be that would handle around 3500 watts as the primary drive off the motor? I would need to be able to get at least VERYclose to 5:1 reduction from it. Anybody know of anything reasonably priced for a lighter power level like this? I figure there has to be something like this out there, I am having problems with my primary chain wearing out tensioner rollers now... I got about 60 or so miles out of it and at $12.00 a piece, its worth it to find a solution. Plus it would be much quieter and smoother!
Click to expand...

I'd love to know the answer to that one too. But do you really consider 3500w as a "light power level"? I'm only looking to run 2000w and I consider it as a resonable size motor. What RPMs is your motor pulling at full power? Bob
Click to expand...

I use 5mm pitch 15 mm wide belts for most applications in that wattage range. I have just gone to 20mm wide for higher power setups. If belt skip is encountered, use an idler to achieve more belt wrap around the motor pulley.

Hey, what town are you in? I am in McHenry (NW of Chicago). You could swing by and see the belts and pulleys I use.

Matt
 
Hey is it possible to find 5mm belt pulleys in a 50-60T Pitch? what would the diameter be of such a thing?
 
recumpence said:
dumbass said:
Whiplash said:
Hey what would the smallest lightest belt/pulley setup be that would handle around 3500 watts as the primary drive off the motor? I would need to be able to get at least VERYclose to 5:1 reduction from it. Anybody know of anything reasonably priced for a lighter power level like this? I figure there has to be something like this out there, I am having problems with my primary chain wearing out tensioner rollers now... I got about 60 or so miles out of it and at $12.00 a piece, its worth it to find a solution. Plus it would be much quieter and smoother!
Click to expand...

I'd love to know the answer to that one too. But do you really consider 3500w as a "light power level"? I'm only looking to run 2000w and I consider it as a resonable size motor. What RPMs is your motor pulling at full power? Bob
Click to expand...

I use 5mm pitch 15 mm wide belts for most applications in that wattage range. I have just gone to 20mm wide for higher power setups. If belt skip is encountered, use an idler to achieve more belt wrap around the motor pulley.

Hey, what town are you in? I am in McHenry (NW of Chicago). You could swing by and see the belts and pulleys I use.

Matt
Click to expand...

WOW Matt, Your not very far from me. I'm in Wayne, ILL about 35 miles south of you (Close to Elgin, ILL). I would love to see your setup especially your belt drive. Any chance of getting to gether sometime soon? Bob
 
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