Rear hub motor disc brake dilemma

[voicecoils]

Sidecover received and installed.

The bearings are the correct ones for my 14mm axle with 10mm flats and the 8" disc rotor screwed on just fine.

I will have to space it out for caliper fit and frame clearance once I have my swingarm back.

Details, photos & video here:
http://endless-sphere.com/forums/viewto ... 35#p133994

I've shown how I popped out the old sidecover with a small gear puller, might help others in the same situation.

Thanks getadirtbike aka John @ www.stealthelectricbikes.com.au

 

[monster]

what about grinding the calipper so that it can fit in the narrow clearance? or what about buying a bigger rotor so that it overlaps the motor cover? if 203mm is the biggest for bicycles what about motorcycles? ignore the fact that the brake mounts would be wrong we can make an adaptor for that.

 

[methods]

If anyone comes along later I have 2 of these setups that I can no longer use.
Unfortunately my hub blew the week before I got mine!

Since I have moved on to non-hub drives and I have no plans to go back to the X5

So I have two modified side covers with bearings and disks.

-methods

 

[Drunkskunk]

what about grinding the calipper so that it can fit in the narrow clearance? or what about buying a bigger rotor so that it overlaps the motor cover? if 203mm is the biggest for bicycles what about motorcycles? ignore the fact that the brake mounts would be wrong we can make an adaptor for that.

Grinding works great. I did on mine and made it work with the narrow stock Clyte adaptor.
I used a BB7 since they have adjustment knobs on both sides, were most just adjust from the back. Now I still have a functional adjustment, and it has clearance for a 10mm space.

 

[monster]

can you get custom disc brake rotors made? if you could get a 260mm rotor then we could just bolt it on to the motor cover and use the clearance after the motor steps away to put our calipers.

 

[monster]

i'm having a crack at the X5 rear disc dilemma this week. i have my hub opened up and bike in pieces and we'll see how it goes.

what i have learnt so-far
i thought single speed freewheels would be a solution to the space problem but it seems there is a sholder on the axle, under the cassette, that means it cant be moved through the dropouts excessively. i will try and stick with the 7 speed cassette but just cut the last gear off to shorten it. the single speed freewheel would only work if you were to grind the sholder of the axle but that might weaken it or cause damage. i think a combo of things will get me there:

-grind caliper head to reduce thickness (already only 13mm)
-remove all washers on right hand side
-small 160mm disc
-cut last gear off 7 speed cassette
-strech dropouts more

hopefully making a disc adaptor at work will be easy. then i just have to adapt my non-disc frame to hold the calipers.

wish me luck

 

[voicecoils]

good luck Monster!

My DH Team X5 build is on the backburner for the moment while I'm working on my red commuter bike w/ bafang hubmotor.

However in my swingarm drop outs, it's a very tight fit with: 8" (203mm) screw on disk and a 5 speed cassette however I think I can get it to work. To get the caliper to clear the sidecover, the disk cannot be screwed on all the way, I'm working on a spacer that will give me just enough clearance for the caliper without the disk so far out that it hits the swingarm. Spacing it will involve tenths of a mm, so it is a tight fit!

On the drive side, the 5 speed screw on cluster fits fine. I'd love to have a 8 or 9speed cassette with a 12t small cog to fit in the frame, but that won't happen. My frame is 135mm spaced but actually sits around 140mm with no wheel bolted to it.

The last issue is rim dishing. I need to dish mine as far towards the disk side of the wheel as possible. This won't be great in terms of wheel strength but it's a compromise to get the rim centered in the frame and inline with the front wheel of the bike.

 

[voicecoils]

can you get custom disc brake rotors made? if you could get a 260mm rotor then we could just bolt it on to the motor cover and use the clearance after the motor steps away to put our calipers.

It's possible that Hal on this forum might be / can do this. It's a good concept for reducing the overall width required for the X5 to fit a disk and multi speed cluster. Will strain the sidecover, but the load is spread out over quite a few bolts. Hal's done this for at least one of his custom frames, some that he's using appear to be using either screw on or IS 6 bolt mount disks. The drawback of the 'mega disk' straight on the sidecover is that you need a custom frame mount for the caliper. This could come in the form of an adapter plate to bolt onto the old frame caliper mount or new tabs welded on. Depends on the frame and the fabrication abilities you've got. Cheers!