GGoodrum
1 MW
I've got Miles, the madCADer (
), to do a drawing. I'll post it in a few... :wink:

GGoodrum said:This looks way too much, to me. I still think all that is needed is a simple two-piece clamp that can bolt to the exist mount. This would be a lot more secure than using U-bolts, and would look a ton better.
GGoodrum said:To keep the whole assembly from rotating, the "top" clamp piece could have a setscrew, if needed, but frankly, I think a 3-4" long clamp is going to be more than enough to counter the torque for what we are talking about.
recumpence said:Of course, I could always torture you and not take any pics. Then you could just wait for it to be rowed across the ocean slowly, get through customs, and eventually make it to your house.![]()
Matt
recumpence said:Mitch,
I am open to anything. My RC helicopters taught me to listen to those who buy products, but keep an eye on production cost. I have thought of a few options for downtube mounting. If this looks to be the main desire of most buyers, I can design an entirely new drive that is layed out specifically for downtube only use. That would be cheaper to make and more elegent. It will be far less universal, though.
Mitch said:In any event other than doing our best to provide constructive feedback we don't need to be concerned. If Matt decides to produce down-tube mount drives he'll probably come up with a solution that is better than either of our ideas![]()
recumpence said:Also, a BB drive typically requires a very low reduction that may be tough to achieve in one stage. Going above about 80 teeth gets expensive and very large for one pulley. But, again, I am open to anything.
Matt
recumpence said:Pretty simple, really. Granted, this won't work for some of the fancy-shaped, non-circular frame tubes, but for many/most setups, this would be perfect. One slight change would be to add a couple of small threaded holes on the end of the small half, so that a plate, or a box could be mounted between the clamps for holding the controller and/or the throttle convertor board.
recumpence said:D,
Your motor should be here soon. My guess would be that it will show up right about when the anodizing is done. It will be very good to see this drive all done. It should look very good. Your application is very unique. So, I am interested in seeing how it all comes together. You and I may have our builds running at about the same pace here shortly.
1clue said:How are you connecting to the rear hub? At one point I saw references to the disc brake mount, and at others I saw discussion regarding what seems to be a custom hub.
1clue said:Another thing, I'm making the assumption that the motors David is making are brushless DC. Is this correct? Sensorless? What sort of costs and what sort of controller are associated with those motors?
1clue said:At this time, my main focus is on transportation with something which is not junk. I don't like a whole lot of the other e-bike solutions out there. In some cases maybe my bias against crappy bikes may be making my decision right away before I get a chance to see the mechanism, and in other cases an ignorant teenager trying to feed me BS turns me off. Anyway, I haven't decided yet on a purely legal (1.5kW) motor or on the monster, but I would like some information on what people are doing about both.
1clue said:Are there overheating problems yet with these motors? I saw references to it earlier in the thread. One possible solution would be to put a button fan in there, powered by a different motor. It sounds like extra everything, except that when I'm trying to get up a hill I don't want to stop because the motor is overheating. Or the controller.
GGoodrum said:1clue said:How are you connecting to the rear hub? At one point I saw references to the disc brake mount, and at others I saw discussion regarding what seems to be a custom hub.
What we are talking about here is driving a chainwheel on the crankset, which has a freewheel.
GGoodrum said:Yes, David's motor will be brushless and sensorless. The motor D and I will be trying out first is an AstroFlight 3210, which is a fairly big motor, by RC standards. The controller we will use is a Castle Creations HV110 model, which is good for 50V and well over 100A. We have a separate project going on to do a special convertor board that will allow a standard ebike-type throttle, with hall sensors or resistive (typically 0-5k ohms...), to control the RC controller, which expects a 1-2ms pulse stream from an RC radio. this board will also have a pot for adjusting a current limit and it will have places for adding four 330 uF caps, which it turns out the controller needs to make it work better in the ebike environment.
GGoodrum said:1clue said:At this time, my main focus is on transportation with something which is not junk. I don't like a whole lot of the other e-bike solutions out there. In some cases maybe my bias against crappy bikes may be making my decision right away before I get a chance to see the mechanism, and in other cases an ignorant teenager trying to feed me BS turns me off. Anyway, I haven't decided yet on a purely legal (1.5kW) motor or on the monster, but I would like some information on what people are doing about both.
This can be easily controlled via the motor selection and current limiting, but most of us doing these early setups are going for lots of power, up in the 5kW range.![]()
GGoodrum said:1clue said:Are there overheating problems yet with these motors? I saw references to it earlier in the thread. One possible solution would be to put a button fan in there, powered by a different motor. It sounds like extra everything, except that when I'm trying to get up a hill I don't want to stop because the motor is overheating. Or the controller.
With the high-quality motors, like the Astro or like David's, I don't expect these to get too much above room temp. The cheaper variants from China, et all, are a different story. The truth of the matter is we really don't know for sure yet how well some the cheaper motors will do just yet.
-- Gary
1clue said:How are you connecting to the rear hub? At one point I saw references to the disc brake mount, and at others I saw discussion regarding what seems to be a custom hub.
GGoodrum said:What we are talking about here is driving a chainwheel on the crankset, which has a freewheel.
1clue said:I'm not sure if I like that. You mean that, A, the chain ring spins, and B, that I need a different crank than my carbon fiber one, and C, the electric motor cares what gear I'm in? Or am I missing the point altogether? Please say it's E, none of the above. In which case, I still don't know how power gets from Matt's drive to the wheel.
I'm actually quite happy with the performance of the Cyclone setup, which runs off a 16s6p 48V/13.8Ah a123-based pack. The Cyclone motor, which has a kV around 70, drives the front crank, which allows use of a Nexus 3-speed hub in the rear. The only fault I find in this configuration is that they use a ridiculously small #40 (1/2") 6T motor sprocket, so it is noisy as hell. Apparently they also use a cheap freewheel in the crank, although it still appears to working okay for me. Eventually, this can be replaced with a higher quality unit, like the White Industries ENO model, but I'm not going to worry about it until I need to. Anyway, with a 55A controller limit, this setup peaks out at about 2600W, but because of the gearing benefit of going through the 3-speed hub, this combo actually outperforms the 24s4p 72V 5303-based setup with a 4110-modded controller set to about 65A.
This surprising performance "boost" by taking advantage of the bike's gearing has started me on this quest now, to convert all my bikes to similar weight-saving configurations.
So David's motor is not done yet? OK, that is fine even if a bit disappointing, for the same reason it's disappointing to the rest of you.
MitchJi said:It's up to you. Pros and cons to both choices. I personally don't see any good reason not to drive via the Crank and think the gearing advantage makes this choice a feature.
MitchJi said:The Astroflight's are fine. I think David's will turn out to be a little better but if you are in a hurry I wouldn't worry about it.
1clue said:Maybe if the chain idler is somewhere in the middle? Say, the second jack shaft replaces my intermediate idler on the recumbent? That might be a happy medium, where I get the back 9 but not the front 3. The jack shaft would need 2 one-ways I think? I don't like the Burley approach toward chain management anyway, but I don't really want to replace my perfectly good carbon crank. Actually let me rephrase that: I really don't want to replace my perfectly good carbon crank.
Serial Configuration I want to use (one chain from crank to gearbox,one chain from gearbox to rear sprockets)
1clue said:MitchJi said:Say, the second jack shaft replaces my intermediate idler on the recumbent?
recumpence said:Anything is possible, it is purely a matter of time and effort.
Matt
deecanio said:thats like a golden ticket to the wonker factory :lol: