Left-Hand Turned Right-Hand Crank Drive + More

[jcerrona]

At the beginning of this year I had built the left-handed crank drive shown in this thread:
http://endless-sphere.com/forums/viewtopic.php?f=6&t=25199&p=378218&hilit=left+hand+crank#p378218

After commuting 17 miles each way most weekdays for several months I decided that I needed a more sustainable solution from a replacement parts standpoint and from my butt's standpoint. My electric bike needed several improvements:
1. Freewheel crank (from Cyclone bikes, Taiwan). This makes long commutes much easier as I can stand up on the pedals and stretch or take a little break with the motor still powering the bike. It's very fatiguing on the back and butt otherwise. I will probably have to replace the freewheel mechanism with one from White Industries soon since the Taiwanese version (Dicta) seems pretty sloppy.
3. Crank drive moved to right side of frame. This removed the necessity to have two right-sided pedals.
2. Battery repositioned from top of rear rack to inside main frame triangle. This improved handling.
4. Freewheel on motor sprocket. I'm in the process of fabricating an adapter for a 13-tooth metric freewheel. This will allow me to pedal and not backdrive the motor/gearhead.

I designed and built a plug-n-play 36 volt, 20 ah LiFePo battery that mounts to the water-bottle mounts on the frame. It has a custom waterproof aluminum enclosure, 30-amp breaker, power kill switch capable of safely switching the full power of the battery, and charging port. The actual battery pack inside is a slightly custom configuration built by Ping. I was very impressed with his fast service, and the quality of the battery/bms.
It won't win any beauty awards, but I have considered trying to sell this integrated battery solution since I haven't found any with the same power output capabilities that can mount to the water-bottle mounts in the main triangle of a frame. The production version would be anodized black. BionX and AmpedBike's solutions are all smaller (36 volt, 10-12 ah). This may be a pipe dream...there are lots of considerations.

 

[amberwolf]

The main issue I would see with making these as saleable packs is that many frames are not going to have quite enough height at the front, or length at the back, etc, to fit the whole thing.

Many others will, and those will fit fine, as long as the bottle mounts are strong enough to take the weight as it vibrates side to side on them. Might be perfectly ok on some frames, and break them right out of others, depending on riding style and road conditions and whatnot.

What you would probably want to add is a clamp at the rear top edge of the pack that clamps around the seattube, so it can't rock or vibrate back and forth, and thus eventually fatigue the bottle mounts out of the downtube.

If you could add a rounded cutout at the rear top edge, a U-bolt could be used to secure it pretty thoroughly, but would require the lid to be off to get at and tighten the nuts inside the box.

A clamping block would work, too, on the back side of the seattube, with bolts running from inside the box to either side of it's cutout, thru the clamping block's end holes, secured there by washers and nuts.