Mongoose Salvo, GNG 1.1 build (in progress)

[Overclocker]

The Mongoose Salvo (size L) was chosen because 1) good price, 2) huge triangle

The GNG in my hotel room in Hong Kong after meeting up with Jon Chan's dad. Very nice guy, he even took me to a hilltop with a good view

Unfortunately in stock form it's probably a belt shredder so I decided to tweak the design a bit. I also got Lightningrod's upper sheets:

Anti seize on parts that I'll probably have to disassemble later on

12s8p samsung ICR18650-26F bonded together in groups of 8.

test fitting...

in progress... suggestions/wisdom most welcome

 

[Overclocker]

sorry for the very slow progress...

pre-fluxed:

[youtube]0ZRwMXL-Rvs[/youtube]

 

[Wheazel]

Looks good! Are those copperwires cell-level fuses?
What kind of flux do you use?

 

[Overclocker]

Looks good! Are those copperwires cell-level fuses?
What kind of flux do you use?

didn't design them to be fuses. 1.0mm diameter btw.

so here it is mounted to a hardtail (for now). after 300kms there IS some noticeable wear on the belt:

 

[jdevo2004]

I like your belt and chain mods.

 

[Overclocker]

I like your belt and chain mods.

thanks but i'm not sure if the mods did any good LOL. here's the belt after 500kms:

 

[Overclocker]

1000km belt life not good enough. time to do chain conversion...

 

[meelis11]

Did you file off sharp edges of both toothwheels? Probably not, do it.
I did and my belt tooths look like new after 900km. Max they were lasted was about 800-900km but breaking belt is due to stock design (wrapping belt over too small tensioner and probably breaking/weakening fibers inside belt). I now modded that too - replaced belt with shorter version 260mm length instead of stock 275mm

 

[Nobuo]

Very very good soldering skills.
Are you using BMS?

 

[r3volved]

Did you file off sharp edges of both toothwheels? Probably not, do it.
I did and my belt tooths look like new after 900km. Max they were lasted was about 800-900km but breaking belt is due to stock design (wrapping belt over too small tensioner and probably breaking/weakening fibers inside belt). I now modded that too - replaced belt with shorter version 260mm length instead of stock 275mm

Do you have a picture of your belt side? What else did you have to mod to fit the 260mm?

 

[meelis11]

Did you file off sharp edges of both toothwheels? Probably not, do it.
I did and my belt tooths look like new after 900km. Max they were lasted was about 800-900km but breaking belt is due to stock design (wrapping belt over too small tensioner and probably breaking/weakening fibers inside belt). I now modded that too - replaced belt with shorter version 260mm length instead of stock 275mm

Do you have a picture of your belt side? What else did you have to mod to fit the 260mm?

I started my build thread today and added belt mod post there too
http://endless-sphere.com/forums/viewtopic.php?f=6&t=68488&p=1032663#p1032663
(it was 475mm length, not 275mm - fixed in my thread)

 

[Overclocker]

Did you file off sharp edges of both toothwheels? Probably not, do it.
I did and my belt tooths look like new after 900km. Max they were lasted was about 800-900km but breaking belt is due to stock design (wrapping belt over too small tensioner and probably breaking/weakening fibers inside belt). I now modded that too - replaced belt with shorter version 260mm length instead of stock 275mm

yep i did. the motor pulley was particularly time-consuming...

i'm also using a much larger backside idler. less back-bending

btw i do a lot of off-roading that's why everything looks dusty LOL. some of my climbs are enough to stall the motor. probably contributed to the belt's early demise.

 

[meelis11]

Did you file off sharp edges of both toothwheels? Probably not, do it.
I did and my belt tooths look like new after 900km. Max they were lasted was about 800-900km but breaking belt is due to stock design (wrapping belt over too small tensioner and probably breaking/weakening fibers inside belt). I now modded that too - replaced belt with shorter version 260mm length instead of stock 275mm

yep i did. the motor pulley was particularly time-consuming...

i'm also using a much larger backside idler. less back-bending

btw i do a lot of off-roading that's why everything looks dusty LOL. some of my climbs are enough to stall the motor. probably contributed to the belt's early demise.

It still looks like some of teeth are still sharp. Maybe you missed some sharp edges?
But id you are almost 1000km mark and belt has not broken - so less backbending must help Did you mod it immediately (no riding in stock conf)?
btw, what is your idler diameter?

 

[Overclocker]

Very very good soldering skills.
Are you using BMS?

i would have to do w/ soldering for now. might get a spot welder in the future

no BMS. discharged as 12s but "folded" and charged as 6s w/ iCharger 106b+

 

[Overclocker]

Did you file off sharp edges of both toothwheels? Probably not, do it.
I did and my belt tooths look like new after 900km. Max they were lasted was about 800-900km but breaking belt is due to stock design (wrapping belt over too small tensioner and probably breaking/weakening fibers inside belt). I now modded that too - replaced belt with shorter version 260mm length instead of stock 275mm

yep i did. the motor pulley was particularly time-consuming...

i'm also using a much larger backside idler. less back-bending

btw i do a lot of off-roading that's why everything looks dusty LOL. some of my climbs are enough to stall the motor. probably contributed to the belt's early demise.

It still looks like some of teeth are still sharp. Maybe you missed some sharp edges?
But id you are almost 1000km mark and belt has not broken - so less backbending must help Did you mod it immediately (no riding in stock conf)?
btw, what is your idler diameter?

30mm

yep i modded immediately

anyway i'm giving up on the belt. i've just hacked the 80t belt pulley and turned it into a "spider" for the new 80T #25 sprocket. motor sprocket is 11T. should give decent reduction. pictures coming soon

PS i believe the only way to make the belt system work is to have at least an 18T motor pulley. but this means a very high tooth count driven pulley if you want a good amount of reduction.

 

[meelis11]

Why you give up - did you brake your belt or does belt skip?

 

[Overclocker]

Why you give up - did you brake your belt or does belt skip?

while out on a ride the belt started giving out a screeching / tearing sound so i immediately headed home since i didn't want to have to pedal back home some teeth on the belt had already partially broken off

anyway here's what remains of the 80t belt pulley

 

[Overclocker]

 

[r3volved]

Did you just lathe down that belt sprocket?

 

[Overclocker]

Did you just lathe down that belt sprocket?

angle grinder. while motor is running

 

[Overclocker]

chain conversion done. 80T and 11T #25 sprockets from electricscooterparts.com

 

[Overclocker]

now enclosed the primary reduction

shall be finalizing the battery box soon

 

[Overclocker]

 

[Hummina Shadeeba]

Maybe just get a better material belt. Is it Kevlar or just fiberglass?

 

[Overclocker]

Maybe just get a better material belt. Is it Kevlar or just fiberglass?

oh i'm done w/ belts the consensus in the huge GNG thread is that the stock motor pulley is poorly designed and has too few teeth