geared kona dirt jump frame SOLD

[flyinmonkie]

No pics yet, but I have ordered more parts. 2 more 5800 zippy lipos on the way as well. It will be all go when it gets here. I'll put up some pics on Friday when I get a chance to. I'll also see about sorting the chains and derailleurs and having a go under human power.

Clay

 

[flyinmonkie]

Did what I could today on the battery tubes. I have attached them together and decided to put them under the down tube. This has also helped me decide how the wires outside the tubes will go. It should end up very clean looking. I also made up some bolts out of threaded rod and some nylock nuts for the controller. Below are some pics of what I have done and how it will look when done. I will be painting the PVC tubes black to match the bike. They should look a lot better then. I will use 2 velcro straps to attach them to the down tube. In the pics they are just taped on.

Clay

 

[flyinmonkie]

The motor spun today! I got one battery sorted and had to plug it in to see if the controller and throttle work. The result, they do as does the watt meter. Still a lot of little things to finish and tidy up while I wait for my other 2 batteries. I need to make up my parallel wire harnesses for the bats and wire in a battery master kill switch. I also need to sort out the new pedal chain tensioner, or a bracket for it as it is a different thread than my old one. Once I do that, I can put the chains on and tune the gears. Work is about to be very busy for a couple of weeks. I hope to find some time to finish it up soon. I am looking forward to having it for the summer.

Clay

 

[AussieJester]

Blow waiting for more packs..plug in what you got arch up the video and make the bike PiiiiSS KiiiWiiiiiii or are ya 'yella' :lol:

Looking good mate, your gunna shit your pants with the power of lipo hahaa well...the controller will at least i blew one of those up with slas pretty easily, all the best mate ...take care and wear a helmet

KiM

 

[flyinmonkie]

Cheers Kim,

If I get it all wired except the other 2 packs, I'll be givin' it hell. I have a feeling they aren't far away though. I'm looking forward to seeing what it will do. I am putting a fuse in the system, so hopefully it will save the controller should there be any outrageous amp spikes.

Your latest bike is looking amazing, but I wouldn't expect anything less from you now. ha ha

Clay

 

[bzhwindtalker]

nice bike, do you have two motors speeds and one speed on the pedal side?
Adam

 

[TopCat]

It makes me cringe looking at your setup flyinmonkie, How are you goingto avoid your leg(s) getting caught in those sprockets n' cogs? Are you going to cover them with some kinda thin plate.

Just thinking of your safety m8 :wink:

Regards
Tom

 

[flyinmonkie]

Cheers Guy,

Adam, I have 3 motor speeds and 3 pedal speeds. The motor gears are on the rear hub and use the rear derailleur. The pedal gears are on the crank and use the front derailleur. That is the idea anyway. I haven't actually tried it yet. It should work fine if I can keep enough tension on the pedal chain with a single speed chain tensioner and avoid the lower chain stay with the motor chain. There is plenty of room between the chains.

Tom, the spinning bits will keep me motivated to keep away from them. Unless I have really baggy pants, I'm not actually that close to them. My motor isn't an RC motor so it spins a lot slower than they do. It should be all good. I'm not overly worried, if I get scared I'll may a cover.

My second pair of bats have just made it to the country so I should see them in the next few days. As I said, work is quite busy so there hasn't been much progress. I'll see what I can do over the weekend, I might get a pedal test ride.

Clay

 

[flyinmonkie]

It Lives!!!! It Lives!!!!

I got the pedal chain tensioner sorted and both drive chains on today. After a quick pedal, I was inspired to plug a battery in and see what the motor would do. It went well, so I taped the battery to the top tube and went for a test ride. I am amazed at 22v from that small battery!!

Over all I am very pleased. The motor mount has a little movement in it (which I thought might happen). I will see what I can do to tighten it up. The gearing is pretty good. The top gear might be a little too much, but I may not use it much, or up the sprocket a little.

I just went for a short ride, but hit a couple of hills to see what it could do. According to the watt meter I pulled abut 82 amps at one point and hit just over 1700 watts. I thought I wouldn't hit 1000ws till I went to 44v. I am excited to see what 44v will do. The motor only got a little warm to the touch, and the controller never broke a sweat.

I still have a lot of little things to tidy up and sort out before it is all done, but it was a good test ride.

Oh, and Tom, my legs weren't even close to the spinning bits.

Clay

 

[TopCat]

It Lives!!!! It Lives!!!!

Oh, and Tom, my legs weren't even close to the spinning bits.

Clay

Glad everythings ok and your up and running m8. I gives you a great feeling when you set off for the first time after all the hardwork you put into a project.

Glad to hear - No pant leg / Spinny bits problems :wink:

Regards
Tom

 

[bzhwindtalker]

you will have fun with your creation lipo has the guts for your bike!

 

[flyinmonkie]

Cheers BZ, it sure does.

I got a lot of little tedious things done today. I now have anderson's on all my batteries. I have sorted one of the LVC boards, and a parallel wire harness. I need to get a few more connectors and some more wire to finish of the second LVC board and wire harness. I ditched the throttle that came with my controller as I did not like it and set up half grip I had. When I did that, I added a resistor and 2 leads for the LVC boards. It was all electronics today, glad it is over. I dislike soldering and wiring. Having the proper tools would help a lot though.

Next week I'll get the extra stuff and a power supply for my hyperion charger. That should be all I need to finish it up. That really just leaves the battery tubes to finish up now. I need to shorten the bolts that hold them together, cut slots for the wires, put the caps on and paint them black. Should be pretty easy to sort them out now.

The last hurdle now is to figure out how to tension the pedal chain to use all 3 gears. I don't think I said it before, but my chain tensioner won't take up the slack in all three pedals gears. I'm not quite sure what I'm going to do to fix that yet, but I'll come up with something. The rear derailleur works great though. I haven't shifted under motor power while riding, I let off the throttle and pedal while I shift. I think this is the best way to keep from tearing any of the drive train up.

I'll get some pics up in the next couple of days. I am going to be very busy with long days at work until mid week or so.

Clay

 

[AussieJester]

Great stuff you Kiwi mofo Once you get this all sorted and
reliable you know your going to want to go faster right :lol: so what will be the next
modification swapping in Astro 3220 on your reduction setup when $$$ allow ?

I despise the electronic side of the builds too mate don't blame you for not liking it, it sucks ass even with right gear
i think i could fall asleep at the desk it bores me that much LoL

All the best sorting the chain tensioning issue and any small details still to do...

KiM

 

[flyinmonkie]

Thanks Kim, yup you got it, but the whole hog from Matt. Then this set up goes on a bike for the wife. ha ha By then it might be a 14kw beast and a motoped. No that will require a lot more savings (but is in my head maybe as motorcycle).

Yup, I'll get it finished up pretty soon and have it to commute on for the summer. Don't fall asleep on your soldering iron Kim, lol. I'm watching your current build with great interest as well. It's looking great as usual.

Clay

 

[bandaro]

dont get me started on the wiring, i just spent 7 hours the other night soldering and making up the charge options, only stopped when i had run out of terminals, at 2 am...

cant wait to see this build going, it should be very nice, it looks very promising so far, congrats man.

 

[flyinmonkie]

I said I'd get some pics up, so here they are. I hope to get some time this weekend to get the bike sorted on 22.2v. I'm waiting on a couple of things to be able to finish the wire harness and add the other 2 packs.

Clay

 

[flyinmonkie]

More little things done today. I set up the other LVC board so it is ready when I get some more wire and andersons. I have one parallel harness sorted and I finished the first LVC board with a second plug to go to the second LVC board. I put a coat of paint on my battery tubes and made up some straps to hold them on the bike.

I also made up small bracket to put between the motor and the water bottle bracket holes on the frame. My custom motor mount and reduction has some flex and the whole thing rotated slightly on my test ride. With my new added bracket, the motor can't go anywhere. The whole motor and mount are now part of the bike.

Some more paint and package up my batteries to go in the tube, and I'll have the bike running on 22.2v while I wait for the last of my parts. While I am doing that, I need to sort out a master switch. I have a battery kill switch to mount and wire in. And, I need to sort a fuse. I am a firm believer in fuses and I know that some of you aren't for them. But, "she'll be right" just doesn't quite cut it for me with electronics. I am debating whether to get a large 90amp fuse and holder or if paralleling 2 smaller fuse holders and fuses will cut it. I am leaning towards the larger fuse if I can find one easily.

Back with pics soon.

Clay

 

[flyinmonkie]

Battery tubes are basically done. Just a few small details, like getting the wires out of the tubes cleanly, putting the master switch on, and getting it all to fit inside nicely. I found out my LVC boards won't fit in the tubes with the batteries, so I have to put them on the outside somewhere. I'll work on that tomorrow and through the week. I also need to look at how I attach the tubes to the bike. I'm not worried about them falling off, but with the straps I have, they slide down the down tube when I hit bumps and end up in the way of the pedals. I have a few ideas, so we will see what works.

So on to the ride. I took the bike out with 2 of the 4 battery packs (22.2v 11.6 ah) I have and in the battery tube. I started at 25v. I didn't have my GPS, so I don't know how fast it goes yet. It pulls pretty good in first and second gear from a dead stop. Third gear is like overdrive. Once up to speed, it just holds me there nicely. I can shift without pedaling. I just let up on the throttle and shift. The momentum of the chain usually takes it to the next gear. Then I just roll on slowly and if it didn't shift before, it slides into gear easily. I tried some of the good hills around here and even a little off road. The bike did well. I only pedaled on a long hill. I am impressed at even 25v what this does with Lipo, this motor was sluggish at best with 24v of lead. The motor never got too hot to hold my hand on indefinitely.

For some stats, for those of you that like them.
started at 25v
ended about 23v
used about 5.3 ah
pulled a max of 99.94v
averaged around 30 amps to 40 amps while cruising (even up most of the hills)

The worst hill is my drive, I peak at 80 amps at the beginning and them hold 70 amps or so on the way up. I don't have to pedal though like I did with my chopper. The bike is solid and rides really well. It pedals easily as well. I need to get a second derailleur to take up the tension on the pedal chain to get the use of the lower pedal gears, but I haven't needed them yet. If I break down, they will be nice to have though. I am very pleased so far and excited to see what 44.4v does.

I know, I know... Pics... Video... They are coming. I may ride it to work tomorrow and do a couple of tidy up things. Then I'll get some pics and work on some video.

Clay

 

[AussieJester]

Great stuff matey! You know, looking at the reduction setup you could just about bolt a Turnigy 80-100-130kv right onto where the current motor is they are about the same size! Might need to swap the sprocket on the non drive side but all be pretty simple upgrade down the track!

Look forward to the video anywayz...

KiM

 

[flyinmonkie]

Thanks Kim, I'm looking forward to seeing your new bike come together. The thudster 2 speed looks awesome. Upgrades for me might be a sram dual drive. I think with the lower power it will be fine. Then a thudbuster suspension seat post. For the high poer build, it will be an HOBI (high output brushless inrunner) ala Matt with his reduction. Possibly a new frame potentially a full susser. That is well in the future though, so lets just getthis one to 44.4v and finished off.

I made a couple of modifications to keep the battery tubes from sliding. A little ultralon foam glued to the outside of the tubes and clove hitching (a knot) the straps to the frame. I have picked up a couple of small plastic containers to house the LVC boards, but I need to figure out how to attache them nicely to the tubes. That is the goal for the weekend.

I rode the bike to work today though, and it was great. No slippage on the tubes at all and everything felt solid as. I only used just over 3 amp hours getting here, so I should be all good for the ride back. I couldn't fit my GPS mount on the handle bars so no indication of speeds and Ican't remember exactly how far it is to work. I'll work on that over the weekend as well.

I will do my best to get pics up some time tomorrow. Video maybe this weekend, depends on the weather. I'm just itching for the wire to set up my other batteries and double the voltage. Damn this small town NZ with nothing in it. Oh wait... That's why I moved here. *looks out window at the sun setting over the snow coverd mountains* Aaahhhh. Ok I can wait.

Later

 

[flyinmonkie]

Sorry about the pics. I had to go into work today the day just disappeared. I will get pics tomorrow. There is no going into work tomorrow!

While deciding how attach the containers for my LVC boards, I figured out that with a little persuasion I can fit the boards in the tubes on end. that way I can put them in the tubes as originally planned. The draw back to that is I need to make new longer tubes. I kind of need to do that anyway and I have every thing I need to do it. So... It isn't that big of a drawback. New battery tubes on the list for tomorrow with pics. That will allow me to get a master switch in place as well. Then all the little bits will be sorted and when HK gets some more wire I can easily jump to 44.4v.

I'll get the GPS on the bike tomorrow and get some speeds. Gee, it's going to be a big day.

On the positive side, I've been riding the bike when I can and did a beer run on it tonight. It is great to ride. I am getting more comfortable and trusting the bike more every time I ride it.

Back tomorrow

 

[flyinmonkie]

I said I'd have pics and here they are. Remember the battery tubes are a little short at the moment and I will be making longer ones. That is why you can see the white bit where the caps aren't pushed all the way on. Also, I will be putting the LVC boards in the tubes with the batteries instead of just tapping them to the outside like it is now. That will clean up and hide almost all the wires. The only wires that will be sticking out will be the battery main wires, and maybe the parallel wires for charging. That will clean it up a lot. Just some small tidying up things from here. I'll work on some video soon.

Clay

 

[AussieJester]

Its come together nicely kiwi going to get some video up of you running across the fields
chasing down a ewe for the night i hope :lol:
Look forward to the next installment anywayz buddy, you v'e done a great job keen to
see how she goes

KiM

 

[deecanio]

Aye, nice work Clay, now show us some action!!!


D

 

[flyinmonkie]

Thanks guys. It means a lot coming from both of you. Your bikes are an inspiration. I'm looking forward to seeing your bike with the new throttle set up Dec. It should be a ripper.

I have my new battery tubes almost all made. I need to bolt them together and paint them. I'll get some pics of how I've put the batteries together as well. I need to adjust my parallel wire harness a little as I've spun one of my batteries around. I also will put the LVC board on the end of the batteries now and they will fit in the tubes. It will take a little tweaking of the shape and size of the boards, but there is room to do it. I'll make sure to post some pics of them as well.

Because I had the batteries out of the tube, I figured it would be a good idea to balance charge them individually. They were both perfectly in balance and in balance with each other. I'm am glad to know they are staying in balance.

More when I have more to show.