E-Trike Project

[AussieJester]

Heeey Miles!! you have been noticeably absent from round these here parts good to see you drop by to checkz up on things hehe eyez 100% better today thanks mate you guys get Visine eye drops in the motherland? works wonders i keep a bottle in the fridge at all times (great for red eyez if your on that partakes in the smoking of whacky tobaccy to LoL :: wink :: ) ...anywayz--->
[b]
Update[/b]


As stated yesterday i would be doing the right side adapter for the disk rotor...here's a few happy snaps and a quick YouTube flick of the final assembly in 'action'

[youtube]EiCUVetNtx4[/youtube]

The lads have just arrived for Thursday drinks so shall cut this update short suffice to say will be moving to the head tube of the frame tomorrow as Matt (1000watt from this forum) dropped me up a suitable diameter head tube (actually bought the head tube attached to frame and forks of BMX bike hehehe along with some seriously thick ali plate thanks again Matt HANDS OFF Doc LoL) shall make some cup holder size attachments for the head tube so i can pop in my 'heavy' duty disk brake enabled forks...also will finish the adapter mounts for the brake calipers.

Ciao for now ladies

 

[deecanio]

Hi Kim,

beautiful work, again 8)
this is shaping up really nice, love the work on the hubs.
Thanks for the tip on the drops, red eye is an hazard i suffer from frequently, must be all the dust :wink:
i notice a few of the usual suspects are MIA - im wondering if there's some secret builds going on in the background????


Cheers,


D

 

[AussieJester]

Thanks for the tip on the drops, red eye is an hazard i suffer from frequently, must be all the dust :wink:

LMAO yes yes the dust thats it damn it to hell...hehe cheers for the comments bud ... I hope they 'regulars' are
working on some projects I love checking in on ES each morning when i wake up to see whats new... If Doc has been busy be VERY keen to see what he's been upto, will be aluminum and light that i know.. anywayz.. time to get horizontal and pop on a movie and finish the last slices of pizza now the lads have left... back tomorrow

 

[RLT]

The build is looking good Aussie; And thanks very much for documenting it so well.

Gee, I do have a lathe, but YOU seem to be able to get things aligned more properly without one than I do with.
Wouldn't it be nice, if just once and a while we, could get something to bolt right in smoothly without turning, grinding drilling and tapping?

Yeah, you do have to be careful of those eyes. Sometimes even with goggles or a full face shield I get stuff (more than mere dust) in mine. A place I worked for a while required everyone that even came near any grinding or cutting machines to wear full face shield over goggles. (I could never see very well through two layers of plastic distortion though).
Got pretty good at doing eye surgery on myself for a few years . Can't do it anymore though, hands don't work very well any more.

 

[AussieJester]

The build is looking good Aussie; And thanks very much for documenting it so well.

Thanks mate Hopefully it might help someone else in the future with one of their projects

Update

I made the first part of the two part caliper assemblies today.
I have used 6mm aluminum plate for the assemblies-->

The second half to these assemblies will be made from steel and welded to the trikes axle housing, the aluminum section will the be bolted to the axle housing mounts.

Be back tomorrow with another update

Kim

 

[AussieJester]

Update

I finished the second part to the caliper assembly this afternoon...

Made from 3.5mm steel, will be welded in place as shown in above pic 3 & 4
I will need to disassemble the trike rear end and remove the sealed bearings before fully welding the mounting plate in place or the heat
may damage the sealed bearings actually more of a will than a may i think. I will tack it in the correct position prior to dis assembly, i'm waiting
on a mate of mine who's a motor body builder to come around to give me a hand literally, i need it held in place as i tack it. Shall be back with
another update tomorrow, i will do the head tube mods mentioned a few posts back and the custom footplates now i have received the ali
checker plate from my mate on Friday..

Thanks for looking

Kim

 

[recumpence]

Lookin very nice indeed!

I love a completely "From scratch" project. This is one of the coolest projects I have seen in a long time.

Keep the pictures coming!

Matt

 

[AussieJester]

Thankyou Matt appreciate the comments, if i can get even close to the standard of your projects i would be extremely happy. You dont 'set' the benchmark you ARE the benchmark

Cheers

Kim

 

[recumpence]

Thankyou Matt appreciate the comments, if i can get even close to the standard of your projects i would be extremely happy. You dont 'set' the benchmark you ARE the benchmark

Aww, sniff, sniff, isn't that sweet? C'mon, group hug, group hug! :wink:

Thanks, Man. I appreciate all the kudos. The only difference between you and I is the type of machinery we are using to fabricate. You would be amazed how many doors open up with even basic milling machines like I have. Also, anyone with your fabrication skills would learn to run them very quickly.

Anyway, I am really enjoying your build. Keep the pictures coming.

Matt

 

[docnjoj]

How the he** do U do that Aussie????? My rotors are way more out of round and they are standard store bought mounts! My alloy looks like it was chewed by beavers compared to yours. How do U do it with just hand tools??????
otherDoc

 

[recumpence]

Lots of filing, grinding, and sanding. And ALOT of time and patience.

Matt

 

[bambuko]

great build Aussie
and thanks for all the photos and detailed description - most useful
I have been following quietly for some time now, but now have couple of questions, I hope you can help me with:
One is about the rear axle arrangement, here detail extracted from picture on page 11:

What confuses me is (what appears to be) a bearing with read arrow pointing to it?
The axle sits in bearings in the grey tube and the hub is fixed to the axle with three prongs so it is not rotating "on the axle" but "with the axle", so I can't see the point of fitting what appears to be a bearing to the hub?

Another question is about axle bearings in the grey tube -when you come to dis-assemble it eventually (to weld brake brackets) I would be interested as to how are the bearings located and fixed in the grey tube?

I look forward to seeing your beast :wink: in action

Chris

 

[AussieJester]

bambuko....bearings arent really necessary in the drive side hub in sense of being there to be used as a bearing would normally be used. It tightens up onto the 3 pronged hub tightly. Let you know how the bearings are keept in place too mate im guess just pressed in.

I didn't get anything done during the day my brother bought his 49cc bicycle up and we were messing about with that most of the morning to mid afternoon, neighbors wouldn't have been to impressed. Anywayz...after dinner tonight i felt energetic and knocked up these footplates to keepz ma feetz in place...

I need to weld everything up tomorrow and get some more bolts to assemble it completely least all the cutting and drilling is done

Thanks for the comments fellas...Im off to bed now im beat back tomorrow...

Kim

 

[bambuko]

...bearings arent really necessary in the drive side hub in sense of being there to be used as a bearing would normally be used. It tightens up onto the 3 pronged hub...

thanks Aussie - I am glad it's not me going bonkers :lol:
still weird (and wasteful) way of using bearings as bushes...

...Let you know how the bearings are keept in place too mate im guess just pressed in...

I guess you are right, but it seems flimsy, particularly on the trike, where side loads on rear wheels are not inconsiderable when compared with "normal" bike

Chris

 

[AussieJester]

...bearings arent really necessary in the drive side hub in sense of being there to be used as a bearing would normally be used. It tightens up onto the 3 pronged hub...

thanks Aussie - I am glad it's not me going bonkers :lol:
still weird (and wasteful) way of using bearings as bushes...

I dunno...you could always use it as a spare when the other side bearings crapped out, cost of the bearings would be less than 10 bucks they are hardened steel prolly cost near as much to make up a hardened steel bush arrangement, I didnt really think it was a major thing :-|

 

[AussieJester]

Small Update

I have decided a springer front end is still the go and since i am unable to buy a fully adjustable springer fork now (due to ChoppersUS not being able to get them anymore) i'm making one


Nothing major done other than buying the springs and rose end joints for the forks<--(not in original plans is an 'upgrade') also cut the flat plate metal required, i have handed this over to my
mate to take to work tomorrow to cut the hole sizes required unfortunately my lil drill press doesn't have the mojo required...quick pic of whats being made-->

Shall have the plates back tomorrow evening so doubtful of an update tomorrow, day after should have a completed springer front end on my trike

Back then fellas

Kim

 

[docnjoj]

Yeah1 I saw his article a thought it was quite do-able for a decent machinist. Luckily I dont ride choppers!
otherDoc

 

[AussieJester]

I'm sure if you needed to Doc you could knock up a mean set of springers

Update

I got a few bitz and piece done on the fabrication of the springer forks this arvo before my dependable bud Flavio dropped off the
steel plate he drilled for me. I am following the plans loosely, I have a few little 'upgrades' i feel will make the forks a lil bit better planned... ONE of those was the addition of rose joint ends on the ends of the spring rods. I got slugged 19 dollars AU EACH for the rose joints :-| NOT HAPPY JAN!!! Most expensive part of the forks, the springs cost ~30 bucks the rest of the materials i have laying about...

I simply welded a couple of nits to a 8mm bolt before grinding the bolt head and nuts round with the angle grinder and then but welded them into the springer rods.

I also knocked up some spring retainers from pipe and flat plate, the plans call for engine block freeze plugs, i didn't happen to have any laying about and saw no reason why they couldn't be made...I have used fork head tube and another piece of pipe along with some 3mm flat plate to make the spring retainers, welded them up, sanded them down on the linisher and gave them a quick spit of etch primer

I know it doesn't seem like much, but the bulk of the work is now done, the forks will all come together quickly tomorrow, shall have more pics of them fitted to the trike come days end tomorrow

Ciao for now fellas

 

[recumpence]

So, with those springers, I'm thinkin a 20 inch, 48 spoke wheel with radial lacing and a pretty dics brake. :wink:

Matt

 

[AussieJester]

So, with those springers, I'm thinkin a 20 inch, 48 spoke wheel with radial lacing and a pretty dics brake. :wink:

Matt

We is thinking slightly differently hehehe be a 24in with twin disk brakes 36 hole ... Still after more of a 'pro-stock' look than a chopper (not that the 20in option wouldnt look schweet...shouldnt it be 144 spoke though ;-P) the springers will only be an inch or so longer than the original mountain bike forks Matt...well thats the plan...will only have an inch or two travel im guessing which is more than enough IMO for a ride that will be used predominantly on the bike path VERY keen to get these done would LOVE to be in the workshop now but its a lil late and the neighbors prolly wouldn't be to impressed with the angle grinder and die grinder going at this hour :: sigh :: Be up at the crack of 10am though and at it hehe

 

[AussieJester]

Update

Well...i didn't quite get finished on my springer forks, i have made more headway and will definitely have them together tomorrow. Again i have veered off the plans and added a threaded end to the fork tubes, the plans call for some plastic chrome looking caps that pop into the end of the tubes, i didn't like the idea. I have welded a nut to a piece of steel i cut to the OD of the fork tube and welded to the top of the tube. An aluminum washer sits on top bolted via 8mm bolt

The fork tube thing-o-ma-jig has been welded in place and the welds given a lil clean up with the flap disk and the bearing holder thing-a-ma-jig sits nice and flat over the weld. (the reverse side has also been welded.) I have tacked the tubes in place to workout my lengths, as seen in the pics will be the final height as mentioned previously in reply to Matts post, the front end now sits slightly higher than when MTB forks were installed...

Back tomorrow with finished forks... :: fingers crossed ::

EDIT: I was just having a read of the (de)structions for John Brains Springer Forks as haha agh dear me, as i haven't actually READ the text up until now ...I'm male what can i say...(de)structions are for wiminez Anywayz John DOES does mention the following

"--If you want to use motorcycle style risers on these forks you will have to put a threaded bung into the 1" fork tubes and weld flat washers to the top of the upper fork plate to cover the fork holes, so you can bolt them together. This way you will have a firm enough mounting to use motorcycle style risers."


So my "improvement" wasn't actually MY idea as i first stated, it is an option that WAS listed in the plans...while i am editing i might as well let you all in on the fact i WILL be using motorcycle style risers also ...

 

[deecanio]

damn.

It never ceases to amaze me the skills you guy have and the speed at which you work!!!
you knock up all manner of custom goodies and in the time it takes me to spray a few parts, lol
more power to ya kim!!!!


Cheers,


D

 

[recumpence]

Pure metal eye candy. Just incredible steel beauty.

Matt

 

[Deafscooter]

Here is what i said ......... Get your own LifePo4 Battery to your projects .....

 

[AussieJester]

Here is what i said ......... Get your own LifePo4 Battery to your projects .....

Cheers Matt and Deec...

DeafScooter(craig)...you dont read OR comprehend so well but that has become rather obvious ... I have not used ANY BATTERIES in this build ...i will be buying a Lifepo4 pack now the price is affordable, this will be happening in a 3-4 weeks if you must know
Back with an update this arvo fellas off for breakfast then hitting the garage Have an nice day

Kim