Electric downhill/freeride bike

[Ratking]

Don't suppose you could run the belt connecting the motors on the inside, as in a 50t sprocket or something with the inside hollowed out and fixed onto the outside of the motor can, so the belt would be enclosed in the frame itself?

Would this be feasible or put too much force onto the can? heat be an issue?

I've been trying that too, I don't have enough space between the motor. I even tried to design a set up where the can itself had gears attached, but no dice
But the idea is good, the problem is that I was too greedy with the idea of building a narrow and small frame. No room for anything

 

[Ratking]

I've been drawing a rear frame in sheet aluminum and I think I have the design that I like and is possible to make without too much hassle.
The great advantage I have with drawing it as sheet metal in Inventor is that I can export every single parts as a flat 2d drawing with bend details and everything I need.

I know 3-d drawings are boring to see, but it will be fun when I have all the parts made

 

[Byte]

Could you show us how the 2D drawing looks? So in unfolded mode?

 

[Ratking]

Could you show us how the 2D drawing looks? So in unfolded mode?

Absolutely, my pleasure :lol:
I suppose you wanted to see the concept and not all the dimensions and such?

 

[Ratking]

I also managed to slim down the drive pulley from 600g to 265g with a couple of holes
Both pulleys will be lighter than one stock, but they are still heavy as a pig
I wonder why they don't make them in aluminum, only from 40t on upwards

 

[Ratking]

Hello

I've been working a bit this weekend, but things are going slower than I thought it would. What you see took too much time, and I still have a lot more to do.
Much time was spent just getting rid off excess material, and I hope to make more progress soon.

 

[Danny Mayes]

Looking good!

D

 

[Ratking]

Hello boys and girls,

Today was the first day working at a school's mechanical workshop near where I live. They actually had pretty good equipment, so I had a pleasant experience.
I made two motor mounts, they are slimmer and have the mounts for the bolt pattern spread wider than the original mount.
The mounts are made so the support bearing automatically will be centered since the motor mount and support bearing have the same bolt pattern.

Here's a few pictures of todays work, slowly but steady

 

[Danny Mayes]

wow, the royal treatment, very, very nice RK.

 

[Ratking]

wow, the royal treatment, very, very nice RK.

Thank you for the kind words, just trying to make it right.
I hope this is the last upgrade I need to make in the first stage, at least for a while

 

[pendragon8000]

hers a my post of a moded mongoose frame
http://endless-sphere.com/forums/viewtopic.php?f=6&t=47452&start=100#p724109

its steel but yeah, its rediculously tough 2mm sheet bent into channel and end platets welded in and cut and welded into frame with gusset / brackets.
EDIT: PS
that looks SICK!

 

[dh-paule]

SICK?
thats a really cool "bomber style" frame

 

[pendragon8000]

 

[Ratking]

hers a my post of a moded mongoose frame
http://endless-sphere.com/forums/viewtopic.php?f=6&t=47452&start=100#p724109

its steel but yeah, its rediculously tough 2mm sheet bent into channel and end platets welded in and cut and welded into frame with gusset / brackets.
EDIT: PS
that looks SICK!

Nice work, shoud ride very well
Yeah, steel is strong and forgiving, especially for me who don't know how strong certain parts of the frame needs to be.

 

[Ratking]

SICK?
thats a really cool "bomber style" frame

Thank you, appreciate it

In reality, the frame is just a copy of a big hit frame. It is just a coincidence that the bomber is almost the same.
I think most would designers would make something like the bomber frame if making a electric dh bike was the goal.
It's just a general design that pretty much every simple-to-make boxed frame would look like.

 

[pendragon8000]

where the swing arm you had desighned? getting there? must be allot of work fabing all the gear box stuff and well prety much everything.

 

[Idontwanttopedal]

How your build going I had a test ride on mine with old 48v headway pack. Had 10v sag lol still flipped as go no rear brake yet. Lol want more power

 

[dustyearlobe]

I have now seen one of these motors running 42v ... you are creating a monster ,cant wait to see this running its ganna be awsome

 

[Ratking]

More work is done, I think it will work out just the way I thought.
I am finished with two new motor axles in stainless steel, hope they are hard enough. Better than the original butter steel at least
I also got the support bearing holder done, only need the last finishing touches, but I won't waste preciouses work time on details just yet, that I can do without any fancy equipment anyway.
The next step is to make a way to tension the belt. I know how I want to solve the problem, and it's very simple and compact. I'm also happy that I don't need a tensioner pulley, they suck for energy and space.

Here's a bunch of more or less interesting pictures, enjoy :lol:

 

[Ratking]

where the swing arm you had desighned? getting there? must be allot of work fabing all the gear box stuff and well prety much everything.

My school just got the gas fir the tig refilled, so I am about to start practicing my welding skills. I got the hang of welding steel and stainless, but aluminum is tricky. But it's just a matter of time

I will make the swing arm when I feel that the welds are good enough

 

[Ratking]

How your build going I had a test ride on mine with old 48v headway pack. Had 10v sag lol still flipped as go no rear brake yet. Lol want more power

Nicely done, I guess you had a great time testing the bike? I have done the same, too easy without a good rear brake :x

 

[Ratking]

I have now seen one of these motors running 42v ... you are creating a monster ,cant wait to see this running its ganna be awsome

I need a monster to satisfy my needs 8)
What isn't better then being able to get a rush every time the throttle is pulled? I hope to make a reliable bike that can take a pounding without breaking.

 

[pendragon8000]

Thanks for all the photos. Your a boss on that mill!

 

[Danny Mayes]

Great progress!

 

[Ratking]

A little more is done, just a few more parts and I can finally drive the bike again.
Spring is coming to Norway, and I love the smell and all the new noises that comes with the warm weather. Especially the sound from two wheeled bikes
I can feel the rush just by listening in the evenings, and my body tells me that it is time to push the limits again. I have a need for speed 8)

Anyway, I took a couple of pictures so you can see the progress. I have been able to mount both motors and pulleys. It seems to line up well, but I have to make a new axle for the driven pulley before I can test. I also need a couple of 4x4x28mm keys for the motor pulleys.

I had a few moments of total happiness when I managed to get the clips and dimples in the motor axles lined up perfectly. I cant explain how good it is to see that all the measurements is bang on :lol: