Trek 830 Rebuild

[Dirt-E-Dan]

Bubba convinced me to start a new thread on the rebuild of my ebike, so here goes. I originally built up my Trek 830 with the HXT 80-100B and put about 220+ miles on it. I hate that motor. It performed really well, but was very unreliable. I had it geared 10.29:1 and I reached a top speed of 48mph! I got tired of dealing with that motor, so I bought a drive unit from Matt a while back. I decided to not mount it over my rear wheel like I did before, so I've been working on some mounts.

Anywho, I haven't been working on it too much, but I recently finished my sprocket adapter for my Saint hub to a 130bcd sprocket. Here are some pics of that process.

This is where I'm going to mount the drive unit.

This should be a nice setup. I'm going to make some covers for it before I start riding it so I don't mutilate my legs. I'm also going to get away from my zip tie technology that is currently used for battery mounting, and build something a little safer.

This is what I'm thinking for my drive unit mount.

What do you guys think?

Daniel

 

[etard]

That's very elaborate Dan! But why not go with the Recumpence drive mounts since you already have the unit? I'm jealous of how perfectly it fits in the most ideal of locations on that hardtail. Well done sir, this should be a nice ride for you. It looks like you have your own mill?

 

[Dirt-E-Dan]

I have access to some manual milling machines, CNC milling machines, a CNC Lathe at my dad's office, as well as some other machines, however, I don't know how to do any of the CNC programming. Our CNC operators helped me out and taught me a little with the sprocket adapter. I didn't know Matt makes some mounts for round tubing? I only know about the trike frame mounts. The mount I designed is offset so I can hopefully correct any chainline problems. Plus, it's just really rewarding to design something and make it .

Also, how likely is it that the drive unit will make the mounts rotate around the tubing because of torque? Will a torque arm of some description be necessary?

Thanks!

Daniel

 

[recumpence]

I make frame mounts for 1.5 inch, 2 inch, and 2.5 inch tubing. The drive unit is centered on the mounts.

They are $75 for the set.

Your mount looks pretty cool BTW.

Matt

 

[dontsendbubbamail]

I have access to some manual milling machines, CNC milling machines, a CNC Lathe at my dad's office, as well as some other machines, however, I don't know how to do any of the CNC programming.
Daniel

Daniel is being a bit modest about the equipment he has access to. We got together a while back and he gave me a tour of the shop. They have the tooling to fabricate any thing you can dream up. Daniel and I hav a goal for 2010 to have our bikes running at the same time so we can go for a ride this summer.

You need to send the motor mount design over to AJ for a helping of his famous holes. Have you though through how you are going to mount the controller and batteries?

My wife broke her ankle, so you may get 2nd seat on the tandem.

Bubba

 

[Dirt-E-Dan]

I think I might purchase some pre-made boxes from Digikey, bolt them together, and mount them in the center of my frame somehow. I'll have a flange or two to mount my controller and other goodies. I'm still deciding though. Any suggestions?

Sorry to hear about your wife's injury, Bubba. I hope she heals up quickly so she can ride with you.

Does AJ specialize in speed holes? I was thinking about drilling 1/2" holes through my 1.137" tubing at a spacing of 1/4" o.c. all the way along every tube of my frame. It should save a lot of weight. Plus my frame will drain better when the paddle boat attachment flips over.

Daniel

 

[Dirt-E-Dan]

Since my last post made so much sense, hopefully this will redeem me a little. I am slowly making progress, but at least it's progress!

I wish I didn't have to put that idler on the drive side, but my chain won't clear the frame if I don't do that. I drew up those drive unit mounts on AutoCAD and a guy at work helped make them on the CNC milling machine. I made that idler bracket on the manual milling machine one afternoon that turned into an early morning... At least it's rewarding.

Up next, battery/gadget box in the center of the frame.

Daniel