Chopper bike with 93% eff motor

[Bluefang]

The bike is essentially ride able now

The following vid is a test of the no load current
[youtube]VmV33IhRxMQ[/youtube]


The only problem is after that i decided to take the bike out for a quick spin before the girlfriend returned to video the bike in action and i managed to destroy the Nuvinci hub i was using driving thru the disc brake side. It cant handle the massive power as it almost threw me off the back of the bike been very very carefull with the throttle knowing it was going to have alot of torque.

 

[Whiplash]

Did it break the tabs off the side cover??!! Good lord that thing is NASTY! Lol!

 

[Ykick]

I think you're gonna need some motorcycle driveline components to handle that....

 

[Whiplash]

Or possibly a slipper clutch of some sort..

 

[Bluefang]

No i just need to get a solid rear hub where the disc side can handle power going in as well as it can handle stopping the bike. Which means any downhill hub that has a reputation of been really strong and heavy. I have one i hope to collect tomorrow, either way i am going to try and stick to push bike parts

 

[hydro-one]

Great progress!! Move over nuvinci, , , , i think you will definetly be getting air with that thing!!!

, so you wont have a rear disc then?

 

[Bluefang]

The motor has pretty strong regen and i have motorbike brakes on the front, i dont have much worry about not stopping. If i find its a problem then maybe i might have to use the drive sprocket as a brake of sorts. But i have not seen many steel 219 chain sprockets yet.

The bike will wheel spin before the front lifts i hope, either way will be fun

 

[hydro-one]

This is so awesome!!!! i cant wait to see it in action!!!! you need rear brake so you can manage your wheelies when you are learning. I am so close to building a DH style bike around this motor!

 

[geeeyejo1]

Wow - just stumbled on this thread - great job, what a beast! Are you building some type of "Tank" around the battery to keep with the chopper theme?

 

[sn0wchyld]

The motor has pretty strong regen and i have motorbike brakes on the front, i dont have much worry about not stopping. If i find its a problem then maybe i might have to use the drive sprocket as a brake of sorts. But i have not seen many steel 219 chain sprockets yet.

The bike will wheel spin before the front lifts i hope, either way will be fun

you could always get one cut... laser cutting is supposed to be resonably cheap, alternatively you could build an adapter to hold a normal brake rotor beside your 219 sprocket...

cant wait to see it in action mate. looking really good.

 

[Bluefang]

I had not thought about building a brake rotor behind the pulley, i will have room and i will need too as i have changed the gearing to 72T on the rear and it has not left much room with the adapter coming close to hitting the chain when warped around the sprocket. Maybe, hopefully i don't need it

With the batteries i am building a lightweight copper tube frame around the batteries to give it some shape then i will get it covered in a wetsuit fabric that will be removed for balance charging etc. Will not be totally water proof but more then enough to cope with rain etc, just not dumping the bike in a pool. Should look something like a tank when done, but hopefully different enough to stand out

Still screwing around with the rear wheel atm as i have had to go wider on the rear hub then the one i bought due to the chain run, it must have been slightly off with the Nuvinci too but i just didnt notice it. Bought a 150mm wide, 12mm shaft DH hub should be here early next week and i ll build that into a 19" rear motorbike rim and mount a fat tire on the bike, more suspension

 

[Bluefang]

I have been playing around with the bike some more while waiting for the hub to arrive. Managed to get out and test it even with the weather been fairly bad. The temporary hub cant be clamped tight enough so its loosing tension on the chain so it jumping abit at the end and the throttle is VERY VERY twitchy so i am not keen on going all out on it till the weather clears up abit But IT WORKS, and its much faster then my other bikes in both acceleration and top speed. Comparing a 5kw 9C hub pushbike and then my recent 9C middrive Nuvinci hub bike running ~5kw.

FYI its still at stock power levels atm so i really need to stop the throttle from been twitchy. I am only slowly rolling the throttle on, when the bike looks twitchy thats when i pull the throttle slightly too much and it trys to pull away from under me

[youtube]bJAKmafG4nQ[/youtube]
This is ment to be sunny Gold Coast, kinda in the edges of a cyclone system of the edge of southern queensland. Nice and windy with a bit of rain

 

[sn0wchyld]

looking good mate!! cant wait to get home now and start work on my own frame mounted monster!! how much power were you running in that vid?

 

[John in CR]

Bluefang,

You can try using the 3 speed switch to tame the twitchiness on take-off. That's what I had to resort to at extreme power. Be really careful if you try switching to higher speed while on the throttle. I can't wait to try the CA3's new torque throttle control option.

I look forward to your impressions once you're fully up and running. I'm sure plenty of people are, since you're the first one running, and the also first one to say "Let's take this puppy to extreme power". I can't wait to tell the factory that we have someone running their little 1500W at 48V motor at 15,000W . Of course I don't think they believe when I tell them that I'm running HubmonsterHE at almost 16kw with no modifications whatsoever. 8)

Stay safe and have a blast!

John

 

[Whiplash]

Looks great and FAST! Be careful!

 

[Bluefang]

Its crazy fast, scared myself yesterday coming home from the wetsuit shop, pulled it full throttle while at about 30km/h and.....almost shat myself.

Still waiting for bits to make it much better, new rim/wheel, new front wheel and a V3 is now on order as the hall throttle is way to twitchy and i think a torque throttle rather then speed would be much much better. Taking it back to the wetsuit shop tomorrow to get the cover made, should be good as the owner had taken a huge interest in the bike and wants to do something good.

Here's the frame the wet suit will be over.


The next question is what color, as i dont want black. They have a lot of colors but they are all fluro. I am thinking white or some contrast to the green.

 

[Spicerack]

Yumyum Yellow?

Looking great- and wow! that's alot of battery you've got there! :wink: Reminds me of the 15kg of batteries I have hanging off my bike...

Can't wait to see some more vid of this thing at speed- talking of which, what sort of speeds is it doing- cruise/full throttle?

 

[Bluefang]

With the change to a smaller sprocket it should be topping out at about 80km/h, i live in suburbia and will be commuting past 2 police stations so i have no need to go any faster then that.....will get there extremely fast tho nice and scary fast.

 

[John in CR]

I'm liking it more and more. Wetsuit stretched over those curves ribs is going to really bring out a futuristic mechanical cheetah look, at least that's how my brain is interpreting it.

As far as the wetsuit cover, how will it be routed? ie how much of your green tubing will be visible?

John

 

[Bluefang]

It will cover all the upper tubing from the seat forward to the fork, So the lower tube with the BB in it and all the tubing under the seat and to the rear will be still visible.

 

[John in CR]

If possible, I think you'll need to bring it over to his shop and stretch some different colors across it to see what works. My initial reacting is matching that green, but then because that would be a bit much either sew in some small strips or shad in some manner to highlight the frame shape. You definitely don't want to lose the outline of the top tube at a minimum. I like the curve you ended up with on all of those tubes in the battery area, so I'd want to highlight all of them.

Maybe as the main piece use white or a blue or a deep green...something that works well with your existing green. Then sew in strips that match your green so they fall right on the tubes they cover. To keep it simple, just a single strip down the center in that florescent green to bring back the top tube in the side view.

John

 

[hydro-one]

Haha that must be quite a ride!!! Videos never seem to show the crazy feeling you get when it goes so fast, however your huge EV grin is the thing that really gives it away!! Be careful, i wouldnt want a throttle connection with salt on it, wet controller or salt bridge between main and throttle wire (for example inside the CA connector is a very common failure point.)

So far all my hubs have been fairly low powered compared to this. and every single time i have run into bad wiring causing sudden accelleration. happened to me so many times, mostly in winter (road salt). with good breaks and a little luck and ripping out power wires , i survived fine. but the main thing that helped me is having a lower power setup. you wont have this protection ......correct me if im wrong.

i think its fair to say i wound never ride that bike in the slush/salt of my winter roads. . . nor would i want to . and im sure you wont be riding in the wet too much

i want wheelies

 

[Bluefang]

Got the bike back from getting the cover made for the batteries and the guy did not really do as good a job as i was after. I don't think he understood how i wanted to have it done and how tight i wanted to stretch it over the frame that was on the bike for the rib effect that john was talking about. Its all good as i am able to take it back on Monday and get the modifications done that i want. Will need to change the tie method that leaves a large gap between the pieces and removed atleast 1 inch of fabric from the front section of edges, should make it pull together much tighter and make the ribs more visible. Got it done in black for now as none of the other colors he had seemed to look good on the bike, I may get a green strip put along the top where the bar used to be, but that depends on the water proof ability of the stitched edges.


Unfortunatly i still don't have a rim to lace onto the hub i now have so i have to wait for next week before i can change it over. Hopefully my V3 CA arrives by then to take care of most of the throttle issues that Hydro-one pointed out. But i have 2 very easily removed power switches that both trigger shutdown, also with a motorbike front end and all the weight in the middle of the bike its very easy to stop with the current brake system.


Flipped the cover around cause i notice it was blue on the inside, now......keep it black and simple or have it blue and stand out

 

[John in CR]

I think I see what you're after. I hope you can pull it off to your liking. If you can get the wires for charging and balancing to a terminal box outside of the battery area or at its surface, a cheap, easy and paintable option would be to wrap it in Dacron and heat shrink it. I want to do that with a faring made with the construction method used for geodesic canoes and boats http://www.gaboats.com/ . If it works to make a 3.6kg canoe, then there must be some good uses on our bikes for non-structural pieces.

John

 

[John in CR]

Haha that must be quite a ride!!! Videos never seem to show the crazy feeling you get when it goes so fast, however your huge EV grin is the thing that really gives it away!! Be careful, i wouldnt want a throttle connection with salt on it, wet controller or salt bridge between main and throttle wire (for example inside the CA connector is a very common failure point.)

So far all my hubs have been fairly low powered compared to this. and every single time i have run into bad wiring causing sudden accelleration. happened to me so many times, mostly in winter (road salt). with good breaks and a little luck and ripping out power wires , i survived fine. but the main thing that helped me is having a lower power setup. you wont have this protection ......correct me if im wrong.

i think its fair to say i wound never ride that bike in the slush/salt of my winter roads. . . nor would i want to . and im sure you wont be riding in the wet too much

i want wheelies

With my motors you need to hard wire and use that insulating paint on the throttle connections, along with proper applications of drip loops. You simply can't set them up in a manner subject to common throttle shorts.

Controlled wheelies is what I want. Justin told me that with the addition of an inclinometer that both anti-flip and wheelie controller are relatively simple programming to add to the CA3. Those would be great additions for the community, so a bunch of you guys should inquire about that functionality to him. Anti-flip is a big safety feature and wheelie control is only a small step away, and multiple voices will be heard a lot better than one fat guy near the equator who doesn't even know how to post videos.

John