Schwinn chopper ebike buildup questions

[RallySTX]

Update time. I currently have an offer in on two hub motors, and purchased yet another OCC chopper. This one will serve as a learning tool, as well as a test mule for parts destined for the Runt. Purchased today from Jeff in Rockford, a used but servicable earlier model of the OCC bike from Schwinn. Already I have learned how to straighten up the forks, and reduce weight by removing fenders and chainguard. This bike has a rear wheel straight enough to allow for decent rear brakes. I think I'll call it the Stripper. Already I'm contemplating a oversized 26 inch front 9C with 44 volts of LIPO. If it handles well with the oversize wheel I will leave it that way and consider raceing it. If not, I know where to get a 24 that will work just fine.

Update, 1/14/11, Itchyknackers was kind enough to beat out the competition and hand deliver a controller for less that the same item online. Also today I submitted a request to Cycle9 to forward a invoice for a NOS 9C 2805 for $111. It's a 26 instead of a 24 but it will fit the bike without the front fender. The forks will be a tight squeeze with only 1mm or so between them and the motor. My only real worry is finding a 5 wire throttle to fit the controller.

Brian L.

 

[RallySTX]

Another update, the stickers and magnets are in! It only took a week, and that's fast arround here.

Sorry if the pic is yellow, I used a cell phone to get it. Also figured out the throttle connector is the three wire one, so a new lefty from Grin will work just fine. Thanks Knightmb for the dedication over the weekend to get things upgraded. I will be sure to make a donation soon.
Brian L.

 

[thewmatusmoloki]

Hey Brian,
The only problem I think you will have with a bigger front wheel is that the v brake mounts will be in the wrong place.
It is a pretty easy fix tho if you can weld, if not a machine/engineering shop can do it for you for 20 bucks or so.
I haven't put together an e-stingray yet myself but here's a west coast chopper that I'm currently working on re-fitted with a 26" front wheel: and the front modded forks
There's no batteries yet but the handling feels better with the bigger wheel just pedaling around, also there is more rubber on the road with the 26"

And IMHO , looks cooler.

 

[AussieJester]

Look what I found for sale on the East coast.

http://nh.craigslist.org/bik/2099713683.html

Pics

Sure makes my wallet ache!
Nrian L.

I knew i recognized those frames, here's mine-->



The headset on them are excellent, tI know where there's a couple of them Jesse James frames
ready to be chopper up for headsets and bottom brackets too. :wink:

KiM

 

[RallySTX]

Well that's the one thing about the standard size OCC bikes they didn't have front brakes. That's the second reason I was willing to even try a larger wheel. The first of course, was the fender being the only thing in the way. Now I just have to wait til tomorrow to see if I actually get the discount price they advertised. I called Cycle9 yesterday and a very nice gentleman assured me that he would place a tag with my name on the rim so it wouldn't get sold on me. He said that the girl who does internet sales wasn't in, but would be on Monday. I am feeling very optimistic about the way things are going. With any luck, I will have a wheel mounted and battery pack here by Valentines Day. I'm hoping to be riding and grinning by St, Patrics Day. That assumes nobody else buys the used batteries I saw, I get this rim, and the controller I got from Itchy does the deed. I am very excited about the idea of being able to ride again. It's been 25 years since I could do that.
Brian L.

 

[AussieJester]

If your only after a 20 x 4.25 rim i know Recumpence has a couple he was going to send me when i could afford the freight costs, perhaps flick him a pm see if he is still wanting to part with them, IIRC he has a silver and a black...

KiM

 

[RallySTX]

It's here, my very first frock motor!

Inside, nicely packed, with no damage, or anything else!

But I knew that when I ordered it. Really, $111. is a steal for one of these. Too bad I couldn't get a rear 20" disk brake compatible for the same cash. I got the standard tourqe arms installed so I can't complain, escept for one little thing. There's no red arrow indicating direction, so I can't figure out which way to put it on! The really cool thing though, is with the trial fit, it showed no interference with the forks. There's about 1/8th inch clearance on each side. I can't wait to get a tube and tire on it next month and start mounting it along with the controller. This summer is gonna be good!
Oh yeah, almost forgot, Kim, Recompence said he would send a replacement rim when I can swing the scratch, so thanks again for the heads up.
Brian L.

 

[RallySTX]

Just in case anyone cares, here's an update. Yesterday, Methods 9C, 5x12, 20 inch rear showed up. As you will aee, it barely fits.

Pretty, isn't it?

three guesses what's wrong with the pic.

As you can see there's plenty of room for inboard tourqe arms. Today, the left hand throttle and extension cable from Itselectric showed up. Also Yesterday, the switch clusters from McDesign showed as well. Nice deals all arround, thanks guys!
BrianL.

 

[RallySTX]

Update, the 9x7, 9C rear is in. Trial fitting and final measurement for tourqe arms will happen as soon as I figure out how to air up the tire and get some spacers. It looks better than I thought a wheel with 100 New York miles on it would. I just hope it works!

Due to overwhelming response, I'll answer the question in my previous post. The wheel was mounted backwards.
Brian L.

 

[RallySTX]

Today I got a tire on the 2805 from Cycle9, and mounted it to the Stripper. Had to blow it up the hard way. Used a bicycle hand pump on an automotive style air can and used that on both tires.

and the wheel mounted.

Brian L.

 

[RallySTX]

Today in honor of Daytone qualifying I present more pics of the Stripper. After rolling the bike arround in the apartment, it became obvious that an oversize front hubbie wasn't a good idea. I could feel the off balance steering already. Not something I want to contend with while under power with one arm. So off came then 9x5 front, and on went the 9x7 rear, originall bought for the spoiler. I need a stack of washers just to mount this pig!

Nice that the chain stays on the rear cog it's placed on. Even though there is plenty of deflection.

Looks like a standard X5 axle should fit the OCC bikes. I got 7.5 inch outside the dropouts. That leaves just enough to add a grade eight nut and washer. But it also means internal tourqe arms. Not an easy thing sometimes.

Anyone want a new front 9x5 in a 26 inch wheel. I only paid $111. It has a new 26x1.75 tire and a self sealing tube, installed yesterday. And it was tested by Cycle9 before they sent it to me. I'll trade for a rear disk 9x5, anybody?
Brian L.

 

[Pedalex]

i found it the easiest way to use the 6speed freewheel that came with my motor and what a luck the smallest was just in line with front chainwhell. finished my chopper this weekend - have a look

http://endless-sphere.com/forums/viewtopic.php?f=6&t=22035

 

[RallySTX]

I'm glad everything lined up for you ok Pedalex. I'm working on tourqe arm designs today. I hope to post them soon, and make them myself within a month or so. I'm gonna have to substitute cold roll for stainless steel though. I don't think my drill and cutting wheel will work on stainless. Hopefully 3/8 inch or 1/2 inch cold roll squaire bar stock will hold up. I plan to pinch the axle between two pieces of stock with 1/4 inch grade bolts about an inch either side of the axle. Then make legs that run to the frame tubes and use u-bolts to fasten them together. All I will have to do is cut to length, drill the holes, and tap them for the bolts. The only thing I don't have is the bar stock, and a tap set. Happy Presidents Day all.
Brian L.

 

[RallySTX]

Ok, after six hours fighting with a ball point pen, I have a new tourqe arm design for the Spoiler. After posting the pic I realise that the total length of the two main bars isn't listed. The big one is six inches or about 153 mm. The medium one is three inches long or about 76 mm. The medium one goes on top of the axle, then the bottom long one is bolted to that, followed by the extendable legs with a stud. Now I gotta do it over because I forgot the extra bolt for the ubolt that goes arround the dropout. This drafting stuff is giving me a headache! I found a local shop that can get me cold roll steel in half inch square bar stock for $15. Then either I pay them to machine it or do it myself.

Not bad for a no hole or frame mod tourqe arm.
Concept drawing up, but rough, and same for revised TA's.

Brian L.

 

[RallySTX]

Finally I have a question worth asking. The drawing below is my forst attempt to design a pack for the bike. I intend to use the Turnegy 22v 5ah packs listed above. Wired as three sets of parallel in series, for a total of 66v at 20ah. Minus one string to start for an easy and cheap 44v 20ah pack. Did I do it right, or should I break out the marshmallows?
Brian L.

Let's try that again.

 

[RallySTX]

Today I rode the Runt to the park for a brake test and pic. Since swapping the original bent rear rim for the less bent rim from the Stripper, I hadn't been able to verify braking ability. I am happy to report that the results are good. The bike will stop within a bike lemgth under normal conditions. And the Stripper is ready for tourqe arms and a rear hub.

Cheers.
Brian L.

 

[Pedalex]

I highly recommend to use a controller with regen braking if your rear hub motor is a direct drive. It really helps a lot though it sounds 'magnetic' and all the people stare at you. I wouldn' want to ride my chopper without it. My rear disc brake is too weak and the front wheel locks to easily - especially on gravel or when the road is wet.

 

[RallySTX]

Thanks Pedalex, I plan to use DD hubs. I already have two rears now. You have a valid point, there are some steep hills that are two or more blocks long. That means I need to buy another controller, the one I got from Itchynackers isn't regen capable. There's still plenty of time to think that out though. I need tourqearms, batteries, and wire work before I can even try anything out. I'm a step ahead on the chargers though, I already own two 25 amp 12v power supplies. I just need to find out if a 12v supply will run the charger I will need to use for those 22v Tournegy 5ah batteries. Somehow, I think I'll need a 24v supply. Oh well, I'll figure it out. Nice to hear from you.
Brian L.

 

[RallySTX]

Progress made on the Spoiler, the 5x12 crawler from Methods has a new skin, and a self sealing tube. Not to mention the original 180mm rotor from the factory fatty. Note the room on both sides. My puny cam doesn't pick it up, but there are two C washers before the grade eight ones I used on the freewheel side. I need to cut a slot in about twenty of those to get them on the wire side on both bikes.

And now for the Stripper, and the now infamous 11x5 from the east coast. Again grade eight washers on the freewheel side to hold the wheel in place for now. Lotsa room there, and on the other side too. Over a half inch on the freewheel side of both bikes. Tourqe arm clearance will not be an issue.

Today's bling shot, to celebrate my 49th Bday on Monday.

Now if I can just find a half inch rotor spacer for each wheel, mabye the machine shop will carve one up for me.
Cheers all.
Brian L.

 

[RallySTX]

New Tourqe arm sent to machine shop. Not bad for using paint to draft, just a bit retarded is all. Got a new hard hat and Nordlocks on the way too. 8)

Here's one for the Spoiler. I'm not happy about the clarity, the holes are all 1/4 inch. I wonder if that will be enough clamping force.

Brian L.

 

[RallySTX]

Thursday I modified the original chain tensioners for the Spoiler. Careful fileing with a round medium file, a vise, and a fair amount of elbow grease, resulted in chain tensioners that will just fit a 9C rear axle. With the factory washers in the circular depressions, they will work as originally intended on a factory rim. That job took three hours. Last week I asked a local shop to cut some washers for me. I did one with a hacksaw on the vise. It looked like a 6 year old had done it. And the slot wasn't wide enough for me. So I took them in and asked for a 1/16 slot on one side so I could pass the sensor wires through them. Three days later the shop owner delivered them to me at no cost. He said he was proud to help someone out that was trying to build something that good. Twenty grade eight washers slotted for free! And the cut is just wide enough for the Hall Sensor wires. Needless to say, they won the contract to build my tourqe arms with 1/2 inch spuare steel stock. I figure one chain tensioner per bike will help with wheel setup, and negate having to cut the factory Hall Sensor connectors.

Any feedback is welcome.

Brian L.

 

[RallySTX]

Thanks Oatnet! Now all I need is a set of black chapps and I'm ready to roll! That is if I ever get the bike finished.

Brian L.

 

[RallySTX]

Mockup designs for battery boxes for both bikes below.

6s 5a packs, in a 2sx4p pack for 44v at 20ah, good enough for arround town.

6s 5a packs, in two 2sx4p packs for extra range, or 88v, now that's the juice!
Brian L.

 

[ryanvm777]

Nice project, nice to see a few more electric spoilers out there. Ive been itchen to get mine runing again. Here is a picture of it, for some idea's. The battery box was hard to figure out. Luckly my brother and freinds solved that problem for me. Right now mine sits in the garage, not working.I never completly fineshed mine. Yours is looken good, let me know if you have any questions. Im no pro, but Ive done a little research and trial and error. Thanx to you and Topcat mabey Ill get mine running again.

 

[RallySTX]

Hello Ryan! THANKS for post, and for the awesome pic of your bike. I have a bunch of questions for you, but mainly I would like to wish you good luck and hope for a speedy recovery for your bike.. I used to live in Ventura, and in TO. Back in the day I would ride my Schwinn World up Portrero Rd, to visit family on the weekends after working at Arby's. Please feel free to send more pix of the bike as others have expressed an interest in setting up a front hub Spoiler. I have been warning people away from using a front hub, how has it worked out for you? I KNOW Topcat will be wanting specifics on your battery box. He posted here about a bike with one VERY similar to yours. I would be interested in adding a extra seat to mine, and am wondering how your bike handled the extra passenger weight. Mainly though, your monochromatic look is awe enspiring, as is your attention to detail. How fast was it? What was the range? Did you modify the front end at all? What voltage, and hotor did you use? I could go on, but I will relent. Thank you for proving yet again, that Ebikes are nice, but Echoppers RULE! 8)
Brian L.