D's RC Drive Kona DC1

[deecanio]

ok so i have fitted everything and everything clears/works just so.
I'm waiting on a 3 speed shifter for the 32/42/52 roadcrank you see fitted which is holding me up, i plan on fitting the front deraileur and getting the pedal side all sorted with good shifts then i will be able to use Matts brackets to secure the modded "foot", the foot brackets hold the foot a couple of mm away from the seatpost so the front deraileur arm simply fits in that gap, i'll have to fit the deraileur and then mark the foot for the new bracket positions, neither the top or bottom hold in the right position as standard.
Now that i know i can bounce my whole weight without impeding anything it looks much rosier for the setup to go fairly easily, i still have the tensioning issue but with all kit on the slack the chain gets under compression is not bad at all, which is a good thing, i plan to tension using the swingarm to hold the tensioner near the extron end, which is hopefully ok?
im down to 1.75" tyres to get my chainline clearences and they look like elastic bands round my rims compared to the 2.7" monsters i had on previously, still they wont go to waste and have "motoped" written all over them
a few more bits and i'll be set, im guessing a ride next week is likely.
One thing i do need help with is the tensioner construction, i have Todds 12t direct drive adapter which i plan to use in the interim as my tensioner, however usually the bearing is in the pulley/sprocket and this is a solid fix so i will have to bearing it at the the other end seems a waste to use the sprocket just for tensioning tho - does anyone know of a 219 sprocket that can be made to have a press fit bearing?


D

 

[dbaker]

http://gokartgalaxy.com/engine_sprockets1.htm

has 3/4 inch bore 18 tooth sprockets, case hardened. Consider a skateboard wheel with a chain groove cut in the wheel OD.

Nice job! Bet you can't wait to get riding on this one! Will the front derraileur be able reach your front chainrings from the seat post with the longer bottom bracket?

 

[MitchJi]

Hi D,

ok so i have fitted everything and everything clears/works just so.

Now that i know i can bounce my whole weight without impeding anything it looks much rosier for the setup to go fairly easily, i still have the tensioning issue but with all kit on the slack the chain gets under compression is not bad at all, which is a good thing, i plan to tension using the swingarm to hold the tensioner near the extron end, which is hopefully ok?

D

Amazing job! It looks like you've addressed all the shortcomings of the original design.

The chain tensioning/interference with the suspension looks a little dicey to me. I hope everything works well!

How about a picture or two of the mounted drive from the left side of the bike?

How many teeth on the 2 pulleys and how many belt teeth are in contact with the small pulley? Matt said 13 teeth in contact (dual 26t pulleys) with a lot of tension worked for connecting dual 3220's that I'm sure had more power (higher kv) than you are running.

 

[Ypedal]

Lookin nice D !!

Room for 2 motors on that thing ?

About the chain tensioner, skateboard wheels do work well , see bottom part of this page :
http://www.ypedal.com/Cyclone2.htm

Is that 219 chain ? looks good and strong.. i like...

 

[deecanio]

hi All,

dbaker,

thx, a skateboard wheel huh, i hadn't considered that but what a good idea, will look tonight and get one ordered, i want to keep thuds sprocket intact incase i go direct drive at some point.
I'm hoping the deraileur will work, i've had it changing gear by hand but won't know until i get the shifter and cable (due today), it should be ok as the new 153mm bb is only offset on the non drive side


Mitch,

The picture shows the chain pinched together with a paperclip just to take out the slack whilst i play, im actually planning on taking the tension up at the other end by clamping on the chainstay and tensioning right next to the extron, this will save me further ballache in the overcrowded crank end, the only issue i cant work out is if the front deraileur will pass the 11t 219 sprocket cleanly enough to give me 3 pedal gears, i will know once the lever arrives and i can set up to pedal test, i think i will just scrape it (literally).
i'lll post some pics of the left side later on, in order to mount the drive at this point the deraileur has to come off, this is just until i mod the foot to fit around the deraileur.
the belt should be ok, im runnnig 26t to 50t but im only running one motor not 2 so i think i will be ok

Y,

you da man, thx for the link, i can do that now i have a piller drill, jeeez just a bench vice,drill and some hand tools make things soooo much easier, i can make bits that would have taken me weeks and a lot of explaining to get done.
Do you have a linky for the wheel? do i need to use a quality skate wheel? inner diameter of skate wheels? (please let it be 0.375" lol )
No room for 2 motors here, lol, barely room for one!!! 219 chain to the rear mate yes.
wait till i get my motoped chassis, then we'll be up for 2 motors, or one of matts 3230's

As a sidenote, i haven't put the sram dd on yet as i found that the axel isn't 10mm with flats it's 8mm however i will knock up some torque arms and run it at some point, lets just get her running again for now


D

 

[AussieJester]

thx, a skateboard wheel huh

Shaped the one i use on my cruiser in drill press using a file too Deec..

KiM

 

[deecanio]

nice, sold.now to fab a bracket, thanks for the steer guys.

D

 

[knoxie]

You still not finished that bike mate!! :lol:

Looking really sweet mate! looks like you are finally nearly there!! is this the longest build thread on the forum? hope you are well and keeping busy, I have been very busy doing lots of other things but still poke my nose in here!! ha ha, make sure I dont get left behind.

Cant wait to see this thing running, I am building up some new packs will have to join you for a ride, take it easy buddy.

Knoxie

 

[Miles]

Hey Paul!

Good to hear from you

 

[knoxie]

Hey Miles

And you! I see you have been quite a regular!! cripes...your bike still holding up? still dont think I have seen anything quite as sweet as that mate, nice to see most of the big guns are still on the board and firing on all cylinders 8) some very interesting movements in Lipo, jeez the spec on them has sky rocketed I need to get some for my electric BMX.

Knoxie

 

[Miles]

your bike still holding up?

Yes. Still going strong. Could do with some better batteries, though....

We really should all meet up, this summer.

 

[knoxie]

Hi

Yes I am sorting out some new cells, mine are very old now yes be cool meet up, be nice to maybe get down and see Jozz as well, I will post some pics when I get my packs built up, I still have tall my bikes and they are all going strong its just the batts that are the weak point so i decided to get the wallet out.

Cheers

Knoxie

 

[Ypedal]

Hey Hey Knoxie !! long time no see ! great to hear from you !

Yes, Lipo on the BMX is awsome !! i was buzzing around the other day with a 3 lb battery ! ( 48v 5ah with a 45 amp controller ! ) .. way more fun than 20 lbs of Lifepo4 !! :wink:

 

[knoxie]

Hey Ypedal

Good to see you too, I had a look at your thread its amazing isnt it all that power from such a small pack? I am going to do something similar as soon as the stock comes back at the German Hobbyking warehouse, looking forward to buzzing through the park again on the KMX and the BMX such fun, the BMX is going to be amazing with such a light and powerful pack, my old point-1 packs got tired quite quickly and 1 bad cell would constantly trip the BMS.

The nice thing with separate packs like this is that they are easier to manage and balance than 1 x big pack, i have also read folks have been replacing cells in them as well which I imagine is tricky but might save the pack, it was way too much trouble to do that with the Point-1 packs, I changed the BMS on 2 of them and that was a nightmare of job. They packed the cells with wax making it almost impossible to split them and reassemble them properly.

Let me know how you get on with your packs, I will be interested to know how they compare with the PSI cells.

Knoxie

 

[Miles]

Paul,

I just checked the Power-Assist archive. My first post there was on July 7 2003, a week after your first post : )

 

[Jozzer]

Yo Paul,

Long time no see!

How about we all get together at one of the TTXGP races this year? Perhaps I can get us all paddock passes and we can show the race teams where it all started
How about Sentterton (norfolk) July 10/11th? Or Brands Hatch in October (give Deec more time to get his bike finished!)? I'm sure we can find a van for your BMX to tow.. :wink: Wher is most central fo everyone?
You'll be amazed at the performance of the newer Lipo's, you may even manage 2 vans this year!

Deec's bike is clearly a life's work, not one of our quick bodge up's

Steve

 

[GGoodrum]

Great to have you both back. :wink:

LiPos are here to stay, for sure. What amazes me is how much better these newer cells are taking abuse, especially if they inadvertently get overcharged. It used to be that you would get fireworks if you charged them just a bit too much, like about 4.35-4.40V. Our resident Captain Destructo, Luke, had to go to extreme levels to get these to pop. Anyway, it is nice to have more of a safety margin now, just in case.

D's bike is finally taking shape. After he's got it all working smoothly, we'll get him to try some LiPos, and then he'll start breaking things.

-- Gary

 

[Ypedal]

heh heh.. belt slippage was a minor invonvenience on Lifepo4, now it's becomming a real problem with lipo... breakage is inevitable !!!

 

[knoxie]

Hi Guys

Yes Miles its hard to believe that isnt it!! 2003! I was browsing before then for ages and almost started my first build back in 2000 using a starter motor :lol: , I then downloaded some plans from an American chap who had made this cool and powerful bike using a 1hp scott motor directly driving the bottom bracket, skipped that and got my USPD.

The PA forum was a great place to hang out and so was VV it was fun back in those days with Ken trough and the like, I remember being truly gutted when that forum closed down. Nice to hear from you as well Steve and yes we must meet up, I have some Lipo on order from HK and like lots of folks am waiting for them to come :? I have everything in place.

I have that really nice Lemco motor up in the loft still must get something done with that now we can feed it lots of fat amps! Cant wait for Deec to get his bike sorted, I still use mine every day, still using a stock BMC in a 26 inch wheel, no shredded gears or any problems keeping the power down to 1KW really helps I tell you, will have to go easy on the throttle when I hook up the lipos.

One of the TTXGP meetings sounds like a good idea, I should be able to make something in July assuming my batteries arrive in time, anyway its good to be back, when I said I have been busy I have been I am now a daddy!! ha ha, I know scary eh! and I am 40 at the end of the month!! ahhh! still love the hobby though and its great to see all the usual on here, I have been keeping an eye on the forums but not had any time to do much, I even still read the PA forum as that can be fun reading about what Randy and Don are up to, even though Randy ruffles a few feathers I always liked him and still think his bike is cool 8)

Right better get back and wash some bottles you may all laugh but I named my son Tyler! ha ha, well at least its his real name he he, right later doods.

Knoxie

 

[deecanio]

congratulations Paul
You are the daddy now for sure, good to see you around again, whats all this about letting the wallet buy some lipo???? if your going to do that you may as well go the whole hog and get some rc kit for a new build
i'll be up for a meet up with you guys anytime, july does sound good to me as i've a few bits to do, i won't be venturing past the sofa whilst the world cup is on mind so its third week in july for me.
hey jozz, whats up?? lifes work for sure, but not with this bike, im going to move it up with my next one.
I've been chipping away at it today, having basic handtools and a piller drill help immensely and i can just crack on, today issues were the deaileur/219 drive sprocket clearence and mounting position/foot mods.
heres some pics as of close of play today, im nearly there but everytime i adjust something i have to test with suspenion compressed etc, so its up on the bench/test/floor/test/bench/test/floor
Anyway all problems resolved everything bollted on properly i'm still able to bounce the suss good with no impedement, close as hell, but no impedement.
I still have to do the tensioner (skate wheel is here) but that means fabbing a bracket, im not daunted tho anymore as getting all this to fit was far harder
your thoughts appreciated guys, especially whilst we are all here like the old days
Again good to see you guys, lets get jozzbikes2 on.

D

 

[deecanio]

........................................................

 

[dbaker]

Great pics! We will all be interested to see if you can shred that GT belt!

 

[knoxie]

Hi Deec

Looking cooler by the day! really nice stuff, my motors are all still holding out really well amazingly, the X5 of course is stonking along nothing to go wrong if you like! the BMC motors are all fine, I still have a couple of boxes of kollmorgen motors in the loft somewhere must dust them down and knock a little electric car up for the lad! got to use the old batts somewhere as well.

Yes got about 55V 10AH of 30C Turnigy on the way who knows when its going to get here, July meet sounds like fun though if my cells arent here by then Id have to borrow a pack from Jozzers TTX bike

weather looks all played out this week mate, be great to see some video of you in action at some point! I have a really nice full suss frame in the garage, I have in mind using the Lemco and a big bunch of batts for a direct drive perm conversion for messing about off road no peddles foot pegs in the bottom bracket style, bout time I got my soldering iron out again! ha ha...

Right lets meet up in July then! thats sorted! I have a car now as well

Cheers

Knoxie

 

[AussieJester]

heh heh.. belt slippage was a minor invonvenience on Lifepo4, now it's becomming a real problem with lipo... breakage is inevitable !!!

You don't need much slip before this happens either YPedal MaN-->

^^first stage reduction belt...the teeth came clean off in a neat little strip


Deec...thats a neat looking work bench you have there mate, I see the Drill press there too
you nearly have as many tools as me when we seeing the first custom bike from the
deecanio Workshop :lol:

OH...and that gold chain you have Deec, thats a Kart chain is it not? Me likes
the look of it...

World Cup faaaark me im soooo over it already every freakin 5 minutes
theres something about it and it hasn't even started! Was way better
when Australia didn't have a side playing didn't hear half as much about it
Upside i guess is, i wont have any shortage of "programming" to put me to sleep,
~2 minutes of SOCCER is all it takes and i'm out like a light
Just hope i don't see any goals scored...HAHAHA as if that would happen in 2 minutes of a Soccer game
then i wont be subjected to grown "men" <--(use that loosely) dry humping each other

KiM

 

[Jozzer]

Congrats on "Tyler" Paul, I guess you will be calling the next one "Jozzer"?
Can certainly lend you a handful of LiPo if yours don't arrive, I'm sitting on a small mountain of them..

Steve