Rix said:
I for got to ask in your last post, but you are oil cooling your motor. Any problems with leakage? ... Anyway, I see why you like oil cooling, it works.
I'll see how my next motor goes. It'll take me all of about 5 seconds to feel if I got the same hub winding or not. In any case I'm going to get some shallow grooves machined in the side covers to nearly double the surface area on them, for heat dissipation, to work with oil cooling.
Yes I like the oil cooling very much. I'd be screwed without it to be honest. Getting the heat from the stator to the outer casing works a treat, because I'm on off throttle all the time. For what I do, the stock sealed air hub was temp redlining as soon as 15 minutes into a ride, in summer. Not much better in winter. Now I'm getting the hub pretty hot, but it self cools quickly when I back off, and I am always riding until 900Wh or more for an intense ride that lasts for about 90 minutes.
I just couldn't see how venting would work for me. I ride through too much dirt and crap. Lower speeds means little airflow anyway. I also like to have my bike waterproofed (as mentioned), so I can lightly wash it, and it looks good and with ease of maintenance (on a clean bike) it also goes good.
With oil, there is no mess at all for me. I have 6203RS bearings with proper oil seals. I do get the tiniest bit of leaking between the axle and the inner bearing race, but it's nothing really. Just a rag wipe once in a while. I'll wipe in inner face of the rear brake disc before a ride, but there's rarely anything there. Breather hole weeping is bugger all. I use castor oil because it has no smell, biodegradable and is so easy to wipe away. When the right side cover is off, tap a thread for a fill bolt. Ensure the bolt end wont touch the windings. Mine is right on the edge of the cavity just outside the winding.
Sealing the side covers is easy. After cleaning the surfaces to be bonded, and thoroughly cleaning inside the motor, just use sikaflex or equivalent. A very thin layer on each cover perimeter will do (any more any you'll struggle to get the cover off again), then mount the cover while the sealant is fresh, and fix all screws. Once in place, add another thin bead of sika to the visible seam. The next day remove all screws, clean the threads a little and reinstall using blue loctite. Job done. Hit the trails and give it heaps!