Intense M3 + Clyte HT3525 + HD video

[Timma2500]

Cool, decision made! I'll get two, one setup for 12s for Mel's bike and 20s for mine.

Jay i like the idea of using a Turnigy watt meter on it, given theres no readout on the 900w models.

I don't mind if they don't charge at the full 900w, even if it delivers 600-700w thats a lot better than the 150w i've been using for the last few years! :lol:


Paul

 

[ROG130]

hi timma well i liked your build so much i sold my big hit frame and my club roost dh8 frame and gone and got a intense m3 frame to do hell thay are not cheap what size frame did you get my one is a med 17"... did you get your frame heat treated ... i found a local car wheel refurb place that will power coat it and they repair alloy wheels so thinking if they weld alloy wheels they must heat treat them to worth a ring me thinks

 

[BATFINK]

ROG, my mate works in a engineering firm who also do alloy wheel refurbishment and having had a few sets done over the years,they blast them, paint them then bake them in an oven to fully harden them,not sure what temperature they bake them at tho but I bet they don't swell up like enormous cinnamon buns the temperature would have to be high enough to affect the aluminium tho, Timma also said he didn't heat treat his frame. 3mm thick aluminium is strong enough if welded properly

Sent using Endless-Sphere Mobile app

 

[ROG130]

thanks batfink for info i have 3mm alloy so as soon as frame comes chop chop tig we go

 

[BATFINK]

I am in the same boat as you. Waiting on a schlumpf drive arriving so I can fit it to my Norco frame and then I'm starting the chop when I know what clearance I need for pedals etc.

Sent using Endless-Sphere Mobile app

 

[ROG130]

keep us posted batfink on your build this is what Endless-Sphere is all about 8)

 

[Timma2500]

hi timma well i liked your build so much i sold my big hit frame and my club roost dh8 frame and gone and got a intense m3 frame to do hell thay are not cheap what size frame did you get my one is a med 17"... did you get your frame heat treated ...

Haha, good move! I absolutely love riding the M3 and i'm sure you'll feel the same way when you finish yours
Put some 200mm DH forks on the front and together with 241mm of rear travel, it makes for a plush ride thats for sure

I think mine is a medium too, well it was before i extended the wheelbase by 80mm, now its more like a large size.

I didn't bother with heat treating it after welding, mostly for cost reasons but also i don't think it really needs it as i don't do jumps which would put the frame under much more stress than normal trail riding. If you like to get air-time, it may be worth while looking into.

thanks batfink for info i have 3mm alloy so as soon as frame comes chop chop tig we go

Get to it! 8)
And start a build thread for it :wink:

I am in the same boat as you. Waiting on a schlumpf drive arriving so I can fit it to my Norco frame and then I'm starting the chop when I know what clearance I need for pedals etc.

I'm liking the sound of these chops!

keep us posted batfink on your build this is what Endless-Sphere is all about 8)

+1

A quick update on the M3.
92kms of trail riding so far and no troubles at all apart from one of the HT's side cover screws working loose which is my fault as i haven't loctited them in yet after drilling the covers. The HT is taking 5.5kw peaks in its stride, it does get warm but a little common sense riding helps keep it alive at these levels. I'm constantly surprised by this motor and glad i went with the HT over the HS for trailriding, its wheely popping abilities to clear trail obstacles make it a ton of fun on the trail while still giving close to 60kph top speed on 20s lipo.

I'm loving having a CA! Its great to be able to have so many functions in one unit, bravo to Justin for creating such a useful tool.

The torque arms are doing their job nicely, its got to the point where i don't bother checking them before a ride now, they just don't allow any axle movement at all.
Pinch bolt torque arms are highly recommended to anyone else who wants reliable axle holding on their bike

I haven't got any further on my copy of Tench's run/charge plug system yet, been too busy just enjoying the bike!
I'll be getting 2 more 10s 5ah nano packs soon to bring the capacity up to 15ah total so i'll get onto the system after i get them.

I ended up getting some 5w 1k wire wound resistors from Jaycar last week so i'll add one of them to the wiring harness as a pre-charge to stop the plug wreaking plug-in spark.


Paul

 

[ROG130]

sounds like you are having fun with the im3 better get a go-pro cam so we can see it in action do some videos like jay
i was going to tell you what bits i have got formy im3 but going to leave it to i start doing it
ps injoy the fun with the im3 for now lol /////as her indoors will want her big hit soon/// more work for you paul but when its finished you will have somebody to race with

 

[ROG130]

JUST WENT TO GET SOME ALLOY TIG Filler Rods
BUT THERE ARE SO MANY TYPES 7059 7057 7050 7051 AND ON AND ON WHAT IS THE BEST ONE SOME HAVE BETTER JOINT strength
AND SOME GIVE 5% silicon gives excellent flow and penetration HELP PLEASE

 

[ROG130]

sorry to be a pest the steer tube on your build looks a bit longer than std
whats the best type of alloy tube to get
as i can not fine a place to get one from yet in uk but still looking
i was going to use the old steer tube and clean it up but thinking better go get a longer one

 

[ROG130]

ps m3 frame come today :wink: very cool going to love doing this build

 

[Timma2500]

Hey ROG130,
Sorry mate i havn't been on here for a few days. Yeah mels keen to got the BigHit finished but is liking the hardtail i set up for her in the meantime.
The GoPro will be coming in a few months, though i don't think my vids will be as good as Jay's :lol:

As far as filler rods go, i used 5356 3.2mm rods cos thats what i had at the time of building. Most welding / fabrication workshops (and me) usually use these cos their a good allrounder.
They worked ok and no sign of any cracks so far. I'll keep an eye out for a few months before powdercoating but i don't expect to find any :wink:

I can't remember how long the steerer tube is, about 130mm long from memory. Diameter wise, its a 41.4mm x 4mm tube from Nova Cycles: http://www.cycle-frames.com/bicycle-frame-tubing/NOVA-HEADTUBE-AL7005-41.4mm-x-4.0mm-x-1000mm.html

They have other head tubes cut to size but i bought a few 1000mm long tubes so i could cut them to whatever length i needed.

Haha, make sure you start a build thread when you start cutting and welding. Its almost a shame to cut the M3 frames up but gee they make for a great ebike when you do

Paul

 

[Tench]

Just checked my alloy tig rods and they are 5356 aswell, they seem to weld well on all the different aluminium jobs i have done with them. Mine are 2.4mm dia though, i might try the larger 3.2's next time i buy some as they do sometimes melt before you get them to the pool.

 

[ROG130]

how is the m3 frame holding up i will be starting to tig my m3 soon so will be starting a new post soon on it its all cut and bent to shape what a bum of a job to bend it but got there in the end it looks good got my tig set up tiging some old scrap alloy before i start it ... i have dun a lot of mig welding tig is not that bad but when it comes to the thin frame then so got some old coke a cola cans to tig up if i get good at them then the frame will go better me thinks :wink: still hope you are having fun with your m3 all the best roger

 

[BATFINK]

Hello again guys, I have sent my frame to the fabricators, they will finalise my designs on the computer and then start the fabrication and then finish with powder coating the frame, thanks forntheispiratin, I will keep you posted on progress real soon, can't wait.

Sent using Endless-Sphere Mobile app

 

[BATFINK]

For the inspiration

Sent using Endless-Sphere Mobile app

 

[Timma2500]

Hey Roger,

The M3 has been running like a champ apart from the throttle sticking wide open while doing a dohnut a few weeks ago, left me off work for a week and in a lot of pain in the ol santa sack area.... :lol: The Ht is still taking 5kw peaks in it's stride, no doubt keeping an eye on temps helps as do the cooling holes.

Frame wise it's not missed a beat, no cracks or any silly buggers so i'm ready to get it powder coated soon after doing a few more frame mods to include a flush mount charging plug and a small bashplate down near the BB to protect the phase wires from log crossings etc. I've ordered some replica factory M3 frame stickers to finish the frame off after powder coating http://www.bikesdecals.com/intense-m3-decals-kit-p-161.html . They include two stickers with your name on them in the sticker kit so i went with E-Intense



Welding wise, you'll have trouble welding up the coke cans due to the anodising on the cans, better to find some off cut pieces of say 1.2 or 1.6mm ally to practise on.
I found welding this frame easy apart from welding the insert to the bike frame, the frame is just so thin that blowing through it is very easy so be careful when you reach that point hey. And make sure you clean the inside of the bike frame part, mine was full of dirt and crap that can make welding even harder.
Apart from that, get your build thread up n running and document the frame build for us :wink:

Hello again guys, I have sent my frame to the fabricators, they will finalise my designs on the computer and then start the fabrication and then finish with powder coating the frame, thanks forntheispiratin, I will keep you posted on progress real soon, can't wait.

Hey Batfink, have you heard back from the fabricators yet? Have they said how long it'll take?

I can't wait to see what you guys come up with!


Paul

 

[ROG130]

glad is all worked out for you and no problems :wink:
i had to re start the battery box as i got it to hot and f.... it up so got some 6082 alloy 3mm thick this time and having another go :lol:
but thats what its all about we can rebuild him and make him better and faster i think i will call my build the 6 million dollar intense m3 build
:lol: but still love building it i added some bits to the new box build i think you will like so keep a look out as its coming soon to a Endless-sphere pc screen soon all the best roger

 

[BATFINK]

Yes Timma, I have been waiting on my friend getting access to the equipment when his boss is on holiday As I am doing it on the cheap so he is going to do it this week coming, he will tack weld it up and I will approve it before the final welding and powder coating, also going to have the cycle analyst build into the frame similar to what you did but I think my frame will be a bit wider so il have it running horizontal across the frame. When I go to see it on Tuesday/Wednesday it should be tack welded so I will take some pix and show you that stage. I can't wait, crap news is I go for acl surgery on my knee at end of August so I hope i can get it all done and have a few rides before then. Will keep you posted as soon as I have some nice pix.

Sent using Endless-Sphere Mobile app

 

[ROG130]

that will be cool batfink hoping to get my one dun this week
will be keeping a look out for them photos i think your build going to be a very damn interesting

 

[Timma2500]

Haha Rodger, yeah the M3 frames aint cheap thats for sure... spewing it got so hot, hopefully your next go at it is more successful
Be patient with it, if it starts to get hot, walk away, have a coffee then come back when its cooler :wink:

Batfink, any pics of the tack welded frame yet? Sorry, i'm an impatient bastard
I'm not far off starting my girlfriend's Bighit frame so i'll be interested to see how your's is going to look!
Ah man, sorry to hear about the acl surgery, i hope the recovery is as painless as possible and as fast as possible so you'll be back on your bike asap

I'm really looking forward to seeing both your frames

Paul

 

[Hyena]

Looking forward to seeing yours all painted and stickered up mate, I'm sure that'll go a long way to making it look more stealthy.

You still planning a trip over this way soon ? I think you said late August from memory ? I'll have to make sure I give the home secretary adequate notice to clear my schedule so we can get out for a ride

 

[Timma2500]

Yeah it'll look better when its powder coated, dunno if it'll ever be stealthy though as i'm still undecided on colour lol :lol:

Nah can't do the trip this year , i was really looking forward to it but it just hasn't worked out in my favour financially lately so i'll try to do it next year, maybe around march(ish). If Mrs Hyena approves your leave of absence form, i'll still swing by Sydney so we can hit the trails


Paul

 

[Timma2500]

Well, the frame finally went off to the powder coater today for a glossy coat of Flame Red
I was guna go white like the last build and to be a twin for ROG130's white Intense M3 but at the last minute decided to be different this time 'round :wink:
Before it went i quickly welded a bit of box section ally under the BB to protect the phase wires from bottoming out on logs etc.

The replica OEM M3 frame stickers finally arrived and will be applied to the frame when its finished getting coated on Tuesday arvo.

I also picked up some goodies on Ebay last week, 2 x RaceFace Next SL carbon fibre handlebars for $20ea + $20 postage - sweet!
They generally retail for over $100ea so i was a happy little camper! Guna have to get a matching seatpost now :wink:


Nothing else to report other than i've started drawing up the my girlfriend's BigHit FSR frame design on some 3mm aluminium and should start cutting it out next week sometime. I'll take some pics as i go through the process and start a build thread for it when theres enough done worth reporting on
Needless to say i'll be busy re-building the M3 next week too

Paul

 

[ROG130]

good for you paul i was going to go for red :lol: but went for white handle bars look very cool i just finished my centre stand today and it works very well so no more leaning on the lamp post or fence will ad photos at weekend