Turnigy HXT Powered Custom Cruiser Worklog

[AussieJester]

awww man...keep on the West Aussie agencies be great to get you west! We then have 2 of the best downhill e-bikes in OZ right here in Perth ... :lol:

KiM

 

[AussieJester]

Some that have read this worklog 'cover to cover' so to speak would be aware the idea of the
stabilisers were inspired from a young chap Darren Lomman whom ~4 years ago developed
a motorcycle with stabilising wheels that can be ridden by paraplegics. In 2007 he was
awarded Young Australian of the year for his efforts.



Darren is now the CEO of Dreamfit Foundation a company
that utilises innovative design solutions so those with a physically disability have the chance to live
their dreams.

Last night i met with Darren at my workshop to discuss both my project and his current and past efforts, i have to say
he is a remarkable individual and it was an absolute pleasure to meet him.



Darren was very impressed with the cruiser's construction and quality of finish...
I was given some insight into how the stabilisers on the Dreamfit motorcyle work also, it
uses pneumatics to operate not only the stabilisers but all the bikes other controls
normally operated by the riders feet, i.e rear brake and gear change. haha Darren also
commented it sounds real cool to with the "psssh" of the pneumatics, that was
enough for me RC Motored Cruiser Mark II wont use linear actuators it will have pneumatic rams!!
"PSSSSSSSSH" "PSSSSSSSSSSSH"

The Dreamfit Foundation runs off donations and is staffed predominately by volunteers
donating their time and skills to projects that will inevitably increase the quality of life
for individuals less physically fortunate. If you wish to help out and become apart of this
Dreamfit Foundation donations page can be found here

I look forward to heading to the Dreamplex myself and seeing first hand the work this company is doing and offer some hands on support to the projects...

KiM

 

[daddz]

wow jester your work amazes me every time i check.
i wonder how the pulley would look with a thatch pattern? i dont know how it could be done, but if it was polished it would certainly reflect the light.
hopefully my humble kit build will be here in a few weeks. when it is=, do ya want to think about swapping trikes?

 

[Hyena]

Last night i met with Darren at my workshop to discuss both my project and his current and past efforts, i have to say
he is a remarkable individual and it was an absolute pleasure to meet him.

Cool. Is he actually disabled himself or just helping out those who are ? Either way good to see him getting the recognition he deserves.

 

[cell_man]

Hi Kim,

Haven't dropped by in a while. Good to see the never ending project is still going strong. Hope you get the belt sorted soon mate.

 

[oldhaq]

AJ, gotta hand it to ya, your bike is awesome! A big clap from me. So far it has my vote for overall E-BOTY).
I haven't read every page, does it have a name?
Rob.

 

[AussieJester]

Soz for late reply i been out and about last few days...new belt arrived for the bike

Hyena- no Darren isn't a para hes able bodied just interested in making life easier for the disabled.

cell_man- hey bud, belt is indeed now sorted, no longer slips off the rear pulley runs dead center on the front pulley
also, actually never had that it has always ran one side or the other..either way belt coming off issues are a thing of the past
the sides work as well as expected

oldhaq- no name for it tiz just blue cruiser to me daddz..my trike frame is still sitting same
spot it has for last 6 months haha have to put it back together for a mate who can get some use out of it
but needs a much smaller motor setup for him... thanx guyz

I have also picked up a new front wheel for the bike along with a 180cm rotor, nothing really wrong with current rotors they are fine for the riding i do but bigger is often best and i think i have a way to gain more room to fit a larger rotor, the rocker pivot on the springer fork is an issue as is, i think though by simply swapping out the existing pivot bolt for a button head cap screw and flipping it around so the nut is on the outside i will gain the clearance required to fit the larger size rotor, then itz Whip up a new adapter for the calliper and I iz done...upgraded front brake and new flash wheel...pics when finished :wink:

ciao for now...

KiM

 

[Hyena]

my trike frame is still sitting same spot it has for last 6 months haha have to put it back together for a mate who can get some use out of it
but needs a much smaller motor setup for him

Just throw a bloody hub motor on it you clown - the last thing a blind man needs to be doing is dicking around with rc drive belts and what not

no name for it tiz just blue cruiser to me

The girls love a blue cruiser

 

[AussieJester]

my trike frame is still sitting same spot it has for last 6 months haha have to put it back together for a mate who can get some use out of it

Yes i thought about this, would have to be geared motor though as mate is moving back up the hill in few months time so he will be literally 400 meters from my house and in some insane hills...speaking of which hehe i went for a ride this morning and tackled the 'test hill' I have filmed Matt on this and my first trike tackling it so how the cruiser go hehe FAST it flew over the top i hit the bottom at ~45km/hr and went over the top at 42km/hr with belt slip from 3/4 the way up!! I will get this on film very soon..oh...that was with wheelchair in tow too

On the way back from this ride though the belt slipping was more noticeable, usually only experienced at top end of the throttle movement when accelerating up hill or from a standard start at full power, it was now slipping on the flat, i got home immediately P.M Recumpence and added first stage sprockets and chain to the order I made late last week, turns out the belt slipping issue is the first stage NOT the final stage as i had thought it was! DoH! Matt.P confirmed this early this arvo, he called in out of the blue quite lucky he did it turns out, i asked him to take the bike for a thrash and see if he could determine the belt that was slipping, he literally made it 20 foot up the hill out of my driveway and the teeth and belt parted company on the primary reduction, simply too much torque for the lil belt and the small amount of wrap the belt has on the smaller pulley, i would estimate now 4500watt would have to be about it for the belts Mr Recumpemce? Anything under its fine soon as I push over the 4500watt it slips. So...#25 chain drive setup for the first stage reduction and the belt (for now) will remain on the second stage, i have also ordered from Mr Recumpence SiR sprocket/chain setup for final drive side, this will be needed in near future regardless when higher kv motors are fitted along with the voltage increase, I put this all down to inexperience, if i had ordered a reduction drive with a chain first stage none of this would be an issue...live and learn...or ask AutoBoT Miles more questions at least

i have grown very fond of the belt drive though and will look into 8mm pitch belts for a possible use in future projects to eliminate the belt slip and clatter of chains :: wink :: ...


KiM

 

[Miles]

I put this all down to inexperience, if i had ordered a reduction drive with a chain first stage none of this would be an issue...live and learn...or ask AutoBoT Miles more questions at least

The cogging point is dependant on torque, static belt tension and the number of teeth engaged on the driver pulley, for a given type/pitch/width of belt..... :wink: What size is the driver pulley on the first stage? If a belt works for the second stage, you can be sure that you can get it to work for the first.....

 

[AussieJester]

What size is the driver pulley on the first stage? If a belt works for the second stage, you can be sure that you can get it to work for the first.....

Pretty sure its 20 tooth (without going out to count it) ~2 more teeth than the standard pulley that comes with the reduction drive 'standard' ...larger would be required for more belt contact but isn't possible...well...not if you still wish to get to the bolts to hold the motor to the reduction drive :wink: ...chain it willz have to be Miles...

KiM

 

[mdd0127]

I did a bunch of research and determined that if you want to use a belt for the first stage and handle up to 6500 watts at 6000ish rpm, an 8mm pitch, PowerGrip2 25mm wide polyester reinforced belt with a minimum of a 28 tooth drive pulley is the way to go. It's actually a little overkill but the next size down(15mm) is a little too small. If the 28 tooth interferes with the motor mount bolts, you could use a taper lock to mount it and just remove it to get at the bolts, or maybe you can drill some lightening holes in the pulley at the mount bolt circle diameter. I don't know for sure about that working on Matt's drive but I did it a bunch on troublesome conveyor drives at the plant. With a two piece front shaft support and holes in the pulley, I could pull motors out really quick, then take then to the shop to get the pulley/gear off. I've got all kinds of belt drive info, both on pdf, and print. If you need any diagrams or part numbers, just let me know. Just trying to contribute to your awesome build.

 

[mdd0127]

Also, we had some machines from Germany that were like really big blanket stitching machines with big spiked roller drives, and needles driven by levers connected to servos. They used a bunch of chains and HTD belts. There were some motors that were very expensive and would get burnt out because the machine would get jammed up pretty frequently. Not to mention fried PLC's ,broken chains, and stripped belts. I was told this was a million dollar machine. Once I convinced the bosses to order some form of torque spike eliminators, machine productivity doubled and maintenance costs were reduced to feeder spikes and routine belt/chain maintenance. There are lots of companies that make torque spike limiters for different applications. I want to put some magnets in the two halves of one with some hall sensors to detect their speeds and interrupt the throttle with a little more resistance when they don't match up. That way you can have a clutch to prevent spikes but can electronically prevent it from slipping very much, or for very long. ICE cars, trucks, and motorcycles definitely have clutches for more than just letting the engine idle when stopped. The clutches also smooth out power transmission to let things live. I think that with the power levels we're reaching, some king of torque spike control is necessary.

http://www.safetorque.com/noframes/

Again, I don't mean to hijack your thread or anything, just trying to help your belts live long healthy lives so you can cruise all over the place on that thing!

Just another tip.

 

[AussieJester]

Thx mdd0127...but its really not of much use now i
will be going with Matts chain/sprocket setup
for first and second stages. 6500rpm is very low rate
new 180kv motors and 66v ill be up around 12000 rpm.

You need to see the setup of the reduction drive mdd0127
mounting a larger pulley than i have now would be
very difficult if not impossible & still access the motor
mount bolts..no biggy really #25 chain setup i have used before
on my trikes, they will do the job no probs

Cheers again though, next build i may call on you for some belt/pulley advice with 8mm pitch setup...

KiM

 

[mdd0127]

Thx mdd0127...but its really not of much use now i
will be going with Matts chain/sprocket setup
for first and second stages. 6500rpm is very low rate
new 180kv motors and 66v ill be up around 12000 rpm.

You need to see the setup of the reduction drive mdd0127
mounting a larger pulley than i have now would be
very difficult if not impossible & still access the motor
mount bolts..no biggy really #25 chain setup i have used before
on my trikes, they will do the job no probs

Cheers again though, next build i may call on you for some belt/pulley advice with 8mm pitch setup...

KiM

Since I had a chain come apart at top speed on my XR600, and seeing some of the absolute destruction broken chains caused at the plant, I've been scared of chains going over 100rpm between my legs! It was weird with chains. Even though they were rated for way more than their application, and sometimes even new chains, when they went, they just went all at once, tearing stuff up in the process. When a belt failed, something just quit moving, or got out of time. Plus, I like the sneaky silence of belts. Although I love the screaming outrunner sound, I'll be using a belt primary, enclosing my motor and force cooling it for, hopefully, ninja style silence. All that said, the chain primary setup at 6500 should be a little more efficient than the belt though and it will definitely sound even meaner. I can't wait to see a video! If I can ever be of assistance, let me know.

 

[Ypedal]

How about doubling the pulleys and running double belts ? ( The red-neck in me going with the tried and true " Add Meat Until it Stops Breaking " method )

I occasionally hear my 1st stage belt jump but only on hard launches from a near stopped condition, i epxect this to worsen once i move to lipo ( come on HK.. get a move on will ya )

 

[AussieJester]

mdd0127- i had a chain break on my Suzuki RGV250 back in the late 80's
changing from 2nd to 3rd at peak rpms, the chain wrapped itself around the front sprocket
cost me several gears and about a grand to fix it...sold the bike soon as I had it running again :lol:

I occasionally hear my 1st stage belt jump but only on hard launches from a near stopped condition

Yup thats when mine did it, doesn't take much though and it goes very quickly
from a belt with all its teeth and no signs of wear to-->



No teeth at all! :|

Mr Recumpence SiR is on the ball, shipping of complete set of sprockets happening tomorrow should be mobile
fingers crossed by weekend if not early the week after.


Mr GGoodrum also has also posted off the battery management system i.e parallel boards, charge controller
and battery medic mod, should see that sometime this week i think, shall post pics of the components
when they arrive.

Tmaster- has also modded a Turnigy Meter for me this is also on route, the meter is 100v capable
so, soon as have Mr Goodrums package and Tmasters i have everything here to make the jump
to 66v ...no belt slip and 66v is kinda scary knowing the power this thing has already, i don't think
the long wheel base is going to be enough to keep the front wheel on the ground it gets light now
and i have to back off slightly...The addition of the new front wheel didn't help matters -->





Also upped to a 180mm front disk AND i didn't have to change the pivot bolt it clears by a couple of millimeters!!!
The stopping power is ridiculous just with the rear brake the cruiser pulls up in shirt time, alot
of weight over the rear wheel i guess, i mean, alot of BEEFCAKE gorgeousness over the back wheel

Should mention also Hal is getting a Colossus motor for me so if hobbycity don't get the 180kv Turnigy
motors in before Colossus happens the 12kw watercooled outrunner will be mounted in the cruiser
until a new frame can be made to mount it, just to "test" the motor you all understand
has to be thoroughly tested

Think thats it for now, shall have to find something to occupy myself with now, no
work to do on the bike, clean (ish) workshop...time for some procrastination

rest and some more sketching..back with more soooonz chaps

KiM

 

[Hyena]

DId you get that rim locally ? I'm looking for a source of cheap wide-ish 24" wheels without having to ship from OS
I think you may have sold me on these colossos motors. Ohnoes, what are we going to exchange jabs about then ?

 

[rodgah]

East coast izzz the best

no

West coast izzz the best.....

 

[AussieJester]

DId you get that rim locally ?

Yeah Tim from Kalamunda cycles tracked it down, took a bit too find a decent rim in silver he said, the
hub i didnt picture before is -->



I didn't pullez it apart to see but it is very smooth ...
Matt.P also mentioned how smooth it was and felt like it could be sealed bearings...?



^^I bought these skewers off ebay as
i really don't like the quick release business...

I think you may have sold me on these colossus motors. Oh knows, what are we going to exchange jabs about then ?

hehee... I'm not that phased about the power so much as the water cooling 8) gives me a reason to
fit a radiator and pump along with more scoops on my bike As too what
jabs we can trade then, well i'm sure your girlish good looks and feminine mannerisms will
keep me with sufficient ammunition for many months to come HiGHSiDE Hyena

Rodgah- WEST OZ ROCKZORZ We have the 3 B's in abundance Biatches, beaches & Booze

My brother called around to help "procrastinate"

some with me, he also bought his bike up for a ride unbeknown to him mine is currently immobile LoL..Few pics of
the very different style of bikes-->

View attachment 3




My cruiser is close to a full 20in wheel longer than the bros MTB, and yes
that is a 24in front he has and a 26in rear :-| BiG Bro isn't like me, more like
J.J...long as it works doesn't matter how it looks

My big brother did his license for 6 months (loss of demerit points) he has used the bike
to get about up until last wednesday when he got drivers license back, still uses the bike though
for local errands, its not electric but its cheaper to run than his car

... more procrastination required 8) ciao for nowz

KiM

 

[John in CR]

What you talking about? I'm running a 24" front 19" rear. There's a lot to be said for a vehicle that you don't have to worry about being stolen. 17 months and counting without a breakdown...Unless you count a wet connector after Luke got hit broadside by an ocean wave. Pretty comes last and will be reserved for bikes to be sold. I guess you think Luke's race car has a pretty paint job and decals.

 

[AussieJester]

What you talking about? .

Quality of finish J.J

Your idea of an e-bike



My Idea of an e-bike



Your bikes are Excellent John, strong and reliable well suited to the tasks they
were built for but not the quality of finish that appeals to me
is what i am saying John. I'm a wanker i like flashy parts chrome alloys carbon fiber
and brand name items. No idea what Lukes race car has to do with anything John
i can say though 99% of the cars running Motorplex 1/4 mile in Perth are works
of art with high attention to detail and paint jobs that cost more than yours
and my bike combined, obviously theres the shoe string budget non sponsored
outfits that have cars little rougher but they still look respectable and run good times.


KiM

 

[02jze]

What do those petrol bikes go like kim ? i have seen them on ebay and a family friend wanted to get one.

 

[AussieJester]

What do those petrol bikes go like kim ? i have seen them on ebay and a family friend wanted to get one.

My brothers can't get to my local shops you see me ride the roads to in the videos without pedalling at the moment haha

If you have them set up with tuned pipes and a shift kit so the bikes gearing is utilised they aren't to bad, any
non frock motor 750watt or higher running 50amp plus speed controller would have no trouble beating their poor
acceleration, the fastest i have heard one go with the happy time motor is ~50mph but even with a shift kit
running bikes gearing they are pretty slow as far as acceleration goes, i have ported and polished my brothers
motor, has tuned pipe and high flow aircleaner, in the process of fitting it with reed vlave atm. Brother used to run shift
kit back when i had my trike, when we rode then my old 1000watt brushed Unite motor in the trike pissed all over the bros ICE bike The freewheel in the crank exploded tgus no shift kit

KiM

 

[02jze]

Note to self stay away.. Haha i thought as much. Plus i dont like the idea of the sound. My bike makes alot of noise for an ebike and i love that but hearing a petrol motor at full revs down the street at midnight is no good around here....