New electric mountain bike frame by Phasor Cycles

[Green Machine]

Sick video! Love the soundtrack...it sounds like your tapping the hollow swingarm.

How long does it take you to build one swingarm in real time?

[nicobie]

Curious if the dropouts are wide enough for the cromotor or the 54 series Xlyte (need 150mm)?

[Rodney64]

Thanks for the video David. Nice to get feed back

[Stone Meadow]

Sick video! Love the soundtrack...

Agreed! Who is the artist, David? I'd like to YT them to hear more...thanks!

[dpearce]

Frame#01 almost ready

I machined a few more parts, some brass inserts that will prevent weld from penetrating where you don't want it to, and save from having to do any grinding.











Stone Meadow / Green machine, the artist is just some random youtube music I picked. The title is Lotus Petals, by David O'Brien and Shu Hong.

Green machine- the swingarm alone takes several hours to build, there are several stages that each take an hour or two. Tack weld together / form it, then come back and fully weld the edges, grind smooth, then put in the jig to add on the bearing carriers, shock tabs and dropouts. It is all pretty labor intensive but I am trying to find ways to outsource some of it to local shops.

Nicobie- I think that this will work for 150mm, I will be certain soon when I will be building one for a cromotor. I am not certain about it until I do though, and if it does work it will probably require a dish to the wheel to compensate for the motor's offset.

I will post some more pictures as it comes along

[dpearce]

Finally coming along... First 3 about ready to ship off. Quite a bit of work to get to this point! But I do enjoy fabricating.







Also made a couple upgrades, I added more batteries to my bike to make it 74V 20Ah, 83.5V hot off the charger. Also added a charging port so I don't ever have to take off a side panel except for balancing.



New derailer guard, I happened to test it today as I went over the bars after going too fast off a jump because of the newfound extra power. I have done this jump a thousand times, someone dug a little kink in the lip and it bucked me right over.



With the 84V setup I have already toasted my V4 and V2 BMC hub motors, both of them the solder melted at the phase wire connection and sucked up into the wires until the connection comes apart. I soldered them back together and they work fine. It is lots of fun as long as you don't use the full power continuously like I have been doing, I need to hook up the cycle analyst to limit the current and only 'uncork' it here and there. I will go and drain it at WOT for 1/2 hr, the CA reading a draw in excess of 80A for extended periods, riding like a motorcycle without pedaling much, that is when it gets too hot and fails. I may just go back to the idiot proof 40A 56V setup and not have to worry about it, but the extra power would be missed.

[Rodney64]

Thanks for the update David and hope you didn't hurt yourself. Coming along nice. Ohzee yours must be the unpainted one at the end, number 4 painted all over it.

Can't wait to see my candy blue frame in the next update.


Regards
Rod

[ohzee]

I was looking at this thread yesterday via my phone and drooling.. Those look pretty damn sweet.. can't wait to see mine a nice deep forest green..

I have also pushed the mac motors to the edge and over slightly.. Ran one at 24s 18s lipo and now 20s Lifepo4.. I bought a 2nd from Lyen just to have
a spare for when It finally melts.. they run so much better imo with all that voltage , but yea the parts are not meant for it so things fail.

Glad to see you making good progress keep it up.

[boostjuice]

With the 84V setup I have already toasted my V4 and V2 BMC hub motors, both of them the solder melted at the phase wire connection and sucked up into the wires until the connection comes apart. I soldered them back together and they work fine. It is lots of fun as long as you don't use the full power continuously like I have been doing, I need to hook up the cycle analyst to limit the current and only 'uncork' it here and there. I will go and drain it at WOT for 1/2 hr, the CA reading a draw in excess of 80A for extended periods, riding like a motorcycle without pedaling much, that is when it gets too hot and fails. I may just go back to the idiot proof 40A 56V setup and not have to worry about it, but the extra power would be missed.

Ditch the solder and crimp them brother! Dont accept no lessor PWR limit.

PS: Beaut Workmanship on these frames. I hope the quality doesnt suffer if you do end up outsourcing the labour.

[korpin]

i believe ONE OF THE WHITE frames is mines...HPC making me a 100 volt set up with 4500-5000 watt motor with cooling holes or "scoops" to suck in air.. .

[johnrobholmes]

The cromotor doesn't require much dishing at all for a regular center, about 5mm if I recall.


If there is more trouble with wires coming unsoldered, I wonder if a braze would work better if a crimp can't work?

[Chalo]

danimal:

What does your CAD program tell you is the mass of the naked frame and swingarm?

This is a well thought out design, but it's getting into the weight and bulkiness regime where it might as well not have pedals.

As for me, having anything wider than the diameter of a bike bottle within the area swept by my femurs makes my pedal stroke awkward and inefficient.

Chalo

[flathill]

Looking good! Heavy bikes for heavy duty. Ever ridden a 50 pound 1940s cruiser? Pedals and rides like a dream on the flatland. The point of ebikes for me
make hills flat.

You may want to think about adding an update to your first post of this thread with the final product pictures.

[Rodney64]

I'm sure they will

[Dudeofdoom]

Is it me or is the green frame the best colour

[ohzee]

Personally I am think a deep forest green , but yea I like green.. The neon type green also looks very sharp.

[Rodney64]

Anyone interested in starting a discussion thread for phasor, I'm happy to kick it off

[Deutch420]

Anyone interested in starting a discussion thread for phasor, I'm happy to kick it off

I'm game. So much progress has been made since this thread started. Would be nice to have a new thread to BS about the frame, what parts people are using etc...

[korpin]

one of those white frames is probably mines..HPC doing electronics around 100 volts 4500-5000 watts with boxxer world cup forks using the newest lightest batteries

[ohzee]

one of those white frames is probably mines..HPC doing electronics around 100 volts 4500-5000 watts with boxxer world cup forks using the newest lightest batteries

Thought I found out who had the 2nd frame , but after going back and reviewing your just repeating yourself NBD Id be doing the same if I was getting one so soon.

Can not wait for the reviews.

[Rodney64]

Ok Deutch that's good, share, discuss & components used sounds good. I'm frame 6 so still away off. Would be good to have someone from the first 3 to start it off.

[Deutch420]

Ok Deutch that's good, share, discuss & components used sounds good. I'm frame 6 so still away off. Would be good to have someone from the first 3 to start it off.

I'm 4th or 5th, David said he was making mine last week. I still am undecided on color.

[ohzee]

I was told mine was 4th so hopefully your fifth

Anyway it looks like frames are close to shipping an exciting time.

[Deutch420]

I was told mine was 4th so hopefully your fifth

Anyway it looks like frames are close to shipping an exciting time.

Yours must be the unpowdercoated one in the picture than! Hehe

[ohzee]

The quote was "I think you are getting frame #4. " so anything is possible.. still I am not that picky just glad to be getting one.