E-bike + carbon frame + 52V. 18650 + BMC motor

[soaresdacosta]

Hello guys,

Im waiting in a important part to arrive next week...more on that later. (Thanks Paul)
In the mean time, I receive a small bending machine, to fabricate my battery box in aluminium.
Im still practice, before I made the final piece.

Luís.

 

[Wolfeman]

Thanks for posting Soaresdacosta, I was looking forward to seeing an update. That is going to be such a nice bike!

 

[Jimboyr6]

Excellent work
Are u cutting the dropouts off and making ur own

 

[soaresdacosta]

Hi guys,

Wolfeman, thanks for tuning in. Always appreciated.
Jimboyr6, no. I'm not cutting the dropouts. A friend member, from this forum, make the plates. Its going to be attached to the existente dropouts. Next week I will receive them, and then you will understand the ideia.

Luis.

 

[soaresdacosta]

Hello crew,

Thanks to a forum member (thanks Paul), my parts, arrive today.
Just a sneak peak.

Luís.

 

[soaresdacosta]

Hi guys,

Just to make shore, my idea will work, try to fit everything with some wood clamps. All looks good.

Luis.

 

[Jimboyr6]

Nice machine work
Are thay abit over the top,
What u gona b pushing power ?

 

[soaresdacosta]

Hello guys,

Jimboyr6, Yes its a little over the top. If this was a perfect world, or, I have access to cutting machines, I make another one with the correct measurements...but, I will make some tuning and then will cut the excess...its gone be fun... :? :?
I will use, one single speed in the back and the same in the front. No need to gears change.

Take care,
Luis.

 

[Jimboyr6]

Perfect i never doubted you,
What power controller are u gona use ?

 

[soaresdacosta]

Hello guys,

Jimboyr6, thanks for your words. I will use a 18x4115 feet controller. 150 volts 50 amps. I have this as a spare controller, and I will use it now.
Today I cut my torque-arms, with a Hand-saw. I thought it was more difficult. Take 20 minutes to cut one, with 1cm .
I still waiting on my 3m dp420 epoxy, to install this. Can not wait.

Luis.

 

[soaresdacosta]

Hi guys,

After a lot of cutting and grinding, all the torque-arms, are ready to install. Looks much better.
Still waiting on 3m dp420 to arrive. Not easy to find and shipped to my Country.
Can not wait to assemble the rear wheel. The Summer time is here...

Luís.

 

[soaresdacosta]

Hello guys,

I already have my 3M epoxy. I bought it from Digi-Key. It was the first time, I bought something from them. It take 36 hours, to take delivery. From the U.S. to Portugal/Europe...and FREE SHIPPING...can you believe? 5 stars.

Luís.

 

[Wolfeman]

I can't wait to see this come together Luis. Is the DP420 for bonding the torque plates to the drop outs?

 

[soaresdacosta]

Hello Wolfeman,

Yes. Its for bonding the torque plates to the drop outs...and, I will have 3 screws, just to reinforce everything.

Luís.

 

[soaresdacosta]

Hello guys,

Today I drill holes on my torque-plates, to put 3 screws on each side.
This screws, combine with 3M epoxy will attache the torque-plates to the dropouts.
Before I mount definitely, I tried everything...without the epoxy.
Its all ready, to be part of the bike.

Luís.

 

[Kepler]

Very nice job on those torque plates. I think you can be confident that they will stand up to what ever punishment you throw at them, even under regen.

Are those the final clamping screws or do you plan to fit something a little more worthy of these plates?

Countersinking some stainless Hex head bolts would finish the plates off nicely.

 

[Wolfeman]

Countersunk stainless hex screws would be perfect. Could even anodize them.

 

[soaresdacosta]

Hi guys,

Kepler, these screws are just for mounting everything. After a lot of work, I will never leave it like that. I opted for this.
Wolfeman, the screws going to be M6 in black or silver. Not decide. I have the 2 options.
The pictures down, are just "mock-up". Everything fits very nice.
I have to sand the dropouts, put the 3M epoxy, the screws and paint everything.

Luís.

 

[Wolfeman]

Very nice Luis! This build is so cool.

 

[Kepler]

Hi guys,

Kepler, these screws are just for mounting everything. After a lot of work, I will never leave it like that. I opted for this.
Wolfeman, the screws going to be M6 in black or silver. Not decide. I have the 2 options.
The pictures down, are just "mock-up". Everything fits very nice.
I have to sand the dropouts, put the 3M epoxy, the screws and paint everything.

Luís.

I thought as much.

Any problems with the disc brake rotor clearing the nuts on clamping the torque plates?

 

[soaresdacosta]

Hi guys,

Wolfeman, Thanks men. Appreciated. You have a very nice build too.
Kepler, I have 5mm between the disc and the nuts. I do not anticipated any problem with the rotor. We will see on final assembly.

I cover the "open" space in the dropouts with some metal epoxy putty.

Luís.

 

[DUBRAVKO]

Everything looks amazing! Realy good work!

 

[Kepler]

Agreed. This is a master class in fitting bullet proof dropouts to bicycle frame.

 

[soaresdacosta]

Hello guys,

DUBRAVKO, thanks men. I really appreciate your words.
Kepler, I'm blushing .I'm far from Master...its the first time I do something like this. Everything fine...for now.
Today I put the 3M. Do not underestimate this product. Its really strong.

Luís.

 

[soaresdacosta]

Hello guys,

This part of the build is finally ready. Again, Thanks Paul.
Its time to put it, in the bike.

Luís.