Bubba's Build 4

[dontsendbubbamail]

I forgot to order the hall effects, so the motor assembly is not quite finished.

Bubba

 

[AussieJester]

nice work bubba (as always)

Your adding hall sensors to the outrunner, be keen on some detailed info/pics of this when you do so mate
i don't wish to have to do the same but in case i do...be nice to see how to go about it, i only just saw a hall sensor the other day didnt have a clue what they even looked like till then haha...

Look forward to next instalment anwayz bubba...best of luck...

KiM

 

[dontsendbubbamail]

nice work bubba (as always)

Your adding hall sensors to the outrunner, be keen on some detailed info/pics of this when you do so mate
i don't wish to have to do the same but in case i do...be nice to see how to go about it, i only just saw a hall sensor the other day didnt have a clue what they even looked like till then haha...

Look forward to next instalment anwayz bubba...best of luck...

KiM

I will take some picture as I put the hall effect into the ring. The wood ring system has worked well for me on my Build 3 bike.

Bubba

 

[dontsendbubbamail]

My tandem had one wimpy 5 mm attachment point. I made a bracket out of 1/4" steel and angle iron that has a 3/8" attachment point. It uses the original 5mm attachment point and hose clamp technology.

Bubba

 

[AussieJester]

It uses the original 5mm attachment point and hose clamp technology.

LOL @ hose clamp technology...tiz a bit on the ghetto side for you though bubba!! Whats next Duct tape LoL...

KiM

 

[dontsendbubbamail]

LOL @ hose clamp technology...tiz a bit on the ghetto side for you though bubba!! Whats next Duct tape LoL...

KiM

Hose clamp technology is second only to duck tape technology. Besides I have a aversion to permanently modifying the frame.

Bubba

 

[recumpence]

No, no, no. Hose clamps come first. The almighty hose clamp is like the wheel, it has truely advanced mankind.

Matt

 

[12p3phPMDC]

Good job on the assembly Bubba!!

What are you using to bond the plywwod to the aluminum?

It seems like a good polyurethane glue like Gorilla outta work pretty well.

Integrating a drive like this would be awesome for a composite wood frame
construction like the wood/carbon 'bent

 

[dequinox]

No, no, no. Hose clamps come first. The almighty hose clamp is like the wheel, it has truely advanced mankind.

Matt

I am afraid I have to disagree, hose clamp technology's volume to usefulness ratio is quite linear, whereas that of DT Tech. is very exponential. The more duct tape you have the more useful it is much faster than hose clamps.

("iT NeEd mo' ducK tApe"). :lol:

Lol seriously though I really like the heavy duty mounting bracket. I might do something similar. Perhaps we should work on a universal version that uses something more reliable than hose clamps and duct tape. I have had some success with ground clamps out of the wiring section at home depot...

 

[dontsendbubbamail]

What are you using to bond the plywwod to the aluminum?

It seems like a good polyurethane glue like Gorilla outta work pretty well.

I used Elmer's waterproof carpenters (yellow) glue to bond wood to wood and JB Weld (epoxy) to bond aluminum to wood. I have tried Gorilla glue, but it is messy and only has a shelf life of about a month after you open the bottle. Gorilla glue works, but yellow glue is a lot easier to work with.

Bubba

 

[12p3phPMDC]

Do you hit the aluminum with 80 grit to knock it up before gluing?

 

[AussieJester]

The more duct tape you have the more useful it is much faster than hose clamps.

Reminds me of the Mythbusters Duct Tape Episode They made a Yacht using duct tape including the sail! /off topic


KiM

 

[dontsendbubbamail]

Do you hit the aluminum with 80 grit to knock it up before gluing?

Yes

Bubba

 

[dontsendbubbamail]

The rack is shaping up. The tandem came with cantilever brakes and I upgraded upgraded to V brakes. Now the brakes are in the way of the rack eyelets. I may not use them and machine a bracket for the seat post to attach the front of the rack.

Bubba

 

[dequinox]

I agree, I'd go to the seatpost too. Especially if you don't need to adjust its height a whole lot. Looks great bubba!

 

[dontsendbubbamail]

A seat post bracket it is. I still have to connect it to the rack. The picture is just of the test fit.

Bubba

 

[D-Man]

Who's going to be the first passenger on the rear seat?

 

[Dirt-E-Dan]

I volunteer! Looks great, can't wait to see it!

Daniel

 

[dontsendbubbamail]

We get a little snow about once or twice a winter and it shuts down the city. I stayed inside and worked on my hall effect ring. Hall effects are spaced at 120 deg with the beveled side facing inside. A little paint and some brackets to keep it from falling off and it will be finished.

Bubba

 

[dontsendbubbamail]

Snow sucks!!! One of these day I am going to build a man cave that I can weld in. My current man cave is attached to the house, so no grinding or welding. I took the tandem outside to tack the front support for the rack. Then I made a brace for the water bottles on my single speed. The water bottle support is not strong enough and it was letting the right water bottle touch the belt. I bolted a piece of aluminum to bottom of the water bottle cadges.

Bubba

 

[dontsendbubbamail]

Finished up the welding on the rack and the hall effect ring today. A little paint on the rack and the drive components will be finished. Next up is mounting the batteries and controller.

Bubba

 

[recumpence]

Looks good, Bubba.

Your designs have evolved into quite a simple, elegent layout.

Nice. 8)

Matt

 

[dontsendbubbamail]

Looks good, Bubba.

Your designs have evolved into quite a simple, elegent layout.

Nice. 8)

Matt

Thanks Matt. I am pleased with this rack based design. It is very easy to adjust the sprocket alignments and the chain tension. I have thought about trying to make it lighter by using aluminum for the rack and adding cutouts to the motor assembly but it may not be worth it. I think the weight of the batteries and motor is so much more then the other components that weight savings may not be significant.

Bubba

 

[dontsendbubbamail]

I just had a nice afternoon visiting with Dirt-E-Dan, VRdublove and Christian. I didn't think to ask Christian if he had a build thread here. Anyway Christian has a trike with dual Astro motors that is currently out of commission with one burned up motor. He had the motors with him and I was amazed at how small the rotor was on the Astro. Dirty-E-Dan had his recumpence drive and Astro motor. Again I was amazed at how small the Astro motor is and how good it looks when mated to a recumpence drive. VRdublove let me ride his trike around the dirt parking lot. I was too chicken to take it out on the road because this was the first time I have ridden a trike, it has lots of power and a novelist like me could get into trouble real fast. Seeing VRdublove coming through the parking lot throwing up a rooster tail of dirt was way kool. Too bad I didn't have a video camera.

VRdublove, Christian, Dirt-E-Dan and myself set a goal of having our bikes functioning at the time sometime this summer so that we can all go for a ride together. If anyone else in the Charlotte, NC area wants to go along, drop me a PM. Maybe we can make something happen.

Bubba

 

[recumpence]

Was VR riding the Astro trike or the E-tech trike? They are both fast.

I feel bad for Christian. He is a great guy, but has been struggling with set screw woes as well as some funky wiring issue that left him with only one motor running. That overloaded the second motor and burned it out.

Anyway, glad you are near them. They are all great guys.

If I lived closer, I would show up for the ride!

Matt