Custom frame, full suspension cargo bike thread

[amberwolf]

Got the question on rear suspension. Which way rear shock must be set up?

Do you have a rear-suspension bike? Examine how that swingarm works, and copy that method, if it works well enough for you. that is what I was going to do for my bikes. (although I am copying a motorcycle swingarm for my big upcoming cargo bike, as I'm using an MC shock for it).

 

[agniusm]

OK, trying to work on the overall look and size:

I would like it to be something like this but i have limited imagination on sizing things:

i will try to fabricate pull handle steering like in a tank and run cable to the front fork. Should be fun
I started wandering if i would cut those aluminium panels (2mm) to form a chassis would that be rigid enough not to use frame? That would surely lighten up the bike
EDIT:
A bit more covered:

 

[agniusm]

Hi. I have a question regarding controller. I have a greentime 72V 50amp controller. I will be running CL HS3540 hub. Is there a potential to mod the controller or more current will kill the hub? If i understand correctly at 50amps i would do 4380 watts hot of charger. If it would be beneficial how far would water cooling allow controller to go? It is not programmable controller so what way it is done?
Here are couple photos of controller, it is 12 FET:

The FETS are IRFB4110. Thought would be nice to get involved with modding controller. For waterblock i thought i would take 2 15x5mm copper flat bars and route a 2mm grove in both of them. Than solder them into one block and drill two ends to solder end pipes in. I would then use termo switch to turn on the pump at certain temp and run it of dcdc. Was thinking on PC water pump at 600L/h.
Any thoughts on this?

 

[agniusm]

Some update. Finally got some machinery so soon gonna start on the frame. I got a band saw, Drilling/milling machine and kemppi mig welder. Build a stove in a workshop for working warm in winter.

 

[ohzee]

Looking good.. confused on how that stove works or we just looking at the back part of it ?

Looks like your setting up pretty nice.. Ill take frame number 2 please :0)

 

[agniusm]

Thanks, thats the back side of the stove but it stays hot for minimum 12 hours, and no need to throw logs to keep it lit. This is just a test frame to prove myself that it is viable to work on something functional yet streamlined and very fast. I will be continuing working on center hub steering and after revising this concept. Yam, yam yammmy. Some nice work is waiting.
Ordered missing cells from victpower to make the last 6S pack for 24S system ant that's most expensive parts done with.

 

[agniusm]

Lack of design imagination and here we go cardboard prototyping:

..and the back part had to be lengthened by 300mm
There is going to be lots of space if i would like to double the capacity of the battery.

 

[agniusm]

 

[bzhwindtalker]

A bit more covered:

I like that one a lot! The pull steering seems located a bit low however?

 

[agniusm]

Yeah, i know This is why i am doing cardboard model to check the sizes. i had to lengthen the back by 30cm to have enough space for comfortable seating and right distance to pull lever steering

 

[SHiFT]

This looks to me like you will be very hunched/crouched.

I imagine you won't have room for your knees forward, and your knees would be fairly high compared to your butt, and have to splay outward.
To get to controls that low, your back will have to be hunched. I don't think it would be comfortable for very long.

See this for a sense of scale and control positioning:

Too high and it's not really that comfortable - I think their are too high.
Too low, and you get odd movement and positioning of the arms - in your design I think you have the wrists flat?

You don't have issues with bending the wrist at an extreme angle, but position for the arms and wrist forced by this would create a motion more like an up-and-down, boat/plane throttle motion, more than a forward-back steer type movement, I think.

 

[agniusm]

This looks to me like you will be very hunched/crouched.

I imagine you won't have room for your knees forward, and your knees would be fairly high compared to your butt, and have to splay outward.
To get to controls that low, your back will have to be hunched. I don't think it would be comfortable for very long.

See this for a sense of scale and control positioning:

Too high and it's not really that comfortable - I think their are too high.
Too low, and you get odd movement and positioning of the arms - in your design I think you have the wrists flat?

You don't have issues with bending the wrist at an extreme angle, but position for the arms and wrist forced by this would create a motion more like an up-and-down, boat/plane throttle motion, more than a forward-back steer type movement, I think.

Yes, the sitting position was odd. I have lengthened the back 300mm. The seat will extend and i think i will get something like chopper style seating. I guess i will adjust it for ergonomics when i start building it. For now it looks good enough to start with.

Started working on some components. My BMS is 60A constant and i thought i will tune it up for a bit more. here are some pics:

I will add thermo switch for the fan.
I have decided to put 2 fans to cool inside of the controller. Should help to up the current a bit:

 

[agniusm]

Started working on this frame:

 

[agniusm]

Got this 20A DC-DC converter of eBay:

Had some progress on rear swing arm:

Modded BMS and controller for water cooling:

 

[SHiFT]

Awesome. I can see you opted for the Terrier brand, 1 Dogpower motor. Good choice.

 

[1000w]

Hi agniusm, I'm looking forward to seeing this cool build take shape.
I finished a cargo bike a few months back and I'm loving it.
http://www.endless-sphere.com/forums/viewtopic.php?f=6&t=41358
I copied this design, http://cetmacargo.com/pages/bikes
If you want any dimensions or angles just let me know.
Cheers,
Matt.

 

[agniusm]

Hi agniusm, I'm looking forward to seeing this cool build take shape.
I finished a cargo bike a few months back and I'm loving it.
http://www.endless-sphere.com/forums/viewtopic.php?f=6&t=41358
I copied this design, http://cetmacargo.com/pages/bikes
If you want any dimensions or angles just let me know.
Cheers,
Matt.

hi Matt. Yes, i was fallowing your build and asked few questions on your thread. Nice build there you had.
This bike is my interpretation and i dont know how it will come out Heavy i'm sure

 

[1000w]

hi Matt. Yes, i was fallowing your build and asked few questions on your thread. Nice build there you had.

Sorry I forgot you asked about the head angle.
Cheers,
Matt.

 

[agniusm]

This thing is gonna be huge. Started on frame (mild steel, 25x25x1.5mm):

 

[agniusm]

Need some help with headset. I have RST capa and the tube is 25.4mm i believe. What headset should i get?

 

[agniusm]

Figured the stuff with headset, just need to get one. Made pivot axle for rear swing arm, just need to weld it in place. Have redone the swing arm using 25x25 box section to be the same as the frame. Fitted support for hydraulic brakes. I think i will have disc brake levers on handlebars and fit a foot pedal for regen. braking.
Porn:

 

[agniusm]

Rear swing arm done except some cleaning and few coats of paint

 

 

[agniusm]

Made some progress on the frame. Looks like it's going to be a tank

 

[Boeckstyns]

Hey Agniusm. Just recently discovered your build thread. It's an impressive build. Looks like it's going to take some effort riding it at low speeds though. Did you figure out the head tube angle? I have a bullitt here that I can measure for you if you're interested. Only thing is it will take a while since I just had a knee operation and can't really move around the next couple of weeks... But great looking build!

 

[agniusm]

Hello and thanks. Actually i did measure bullitt headtube angle from the drawing they have on theyr website, the black picture with dimensions. Cant even remember what it is as i implemented it into my sketch and working by the sizes from there. I was frighten at first on handling this machine but then i thought myself there are far heavier 2wheelers there like Goldwings, big harleys etc. On top of that i will try and implement automatic stand with electric actuator when ignition is of.