No pedals bike build blog (from scratch)

agniusm · Oct 31, 2013

i have this HS3540 motor and water cooled 50A greentime controller that was meant for cargo bike. After testing it out looks like its too weak. I decided to go ahead and try sketch a frame to get the bike done without purchasing additional components. I wander how the bike will handle if i have 20" wheel at the front and 26" wheel at the back?
i like those F-117 Nighthawk fighters, no wander why most of my sketches end up with sharp lines. another thing is that it it easier to get my sketchup 3d models into 2d.
Here is what i came up with:

So far its just a shell with some additional panels, most of the other components will be build inhouse. i recently came up on unfold tool for sketchup. this is good to get the sketches into 2D and then its just a matter of exporting it to dwg/dxf and fixing it with corel, then off to plasma CNC which are close to my place:

All the parts would fit on 1250x2500 steel sheet. I think i will try and use .8mm thick material.
Input welcome.

d8veh · Oct 31, 2013

When you make a plan for a bent-up fabrication, you have to add bending allowances, which depend on the thickness and angle, otherwise it won't fit.
http://en.wikipedia.org/wiki/Bending_(metalworking)

agniusm · Nov 1, 2013

Thanks, somehow never thought about that. I will load my model into Inventor and get it done. Shouldnt be too hard

cwah · Nov 1, 2013

yeah that's what happen with my 5mm foam sheets. when I bend them I loose almost 5mm due to corner.

not sure we can do anything with the unfold tool in sketchup

jimw1960 · Nov 1, 2013

this will be fun to watch.

agniusm · Mar 21, 2014

So i thought its time for me to have a proper powered bike. i ditched the idea to do it from sheet steel. I started with 25x25x1.5 steel tube for frame and aluminium box. Here is first progress:

First try to make a seat:

Got some argon, so had a chance to go at aluminium welding. Its not that easy as it looks :shock:

I will use my watercooled 12fet controller. Have bought radiator, pump and other bits. 19AH A123 24S battery. 20" rims with moped tires.
I have swapped my HS3540 RWD for X5303 FWD. I will be drilling side covers, swapping wiring, have an idea of channeling air flow through rear swing arm design. Dont know if that will b a good idea or not.

AussieJester · Mar 22, 2014

great progress so far reminds me a little of ES member Rodgahs stainless steel cruiser..
look forward to seeing the swing arm with incorporated vented cooling, great idea!

KiM

Punx0r · Mar 22, 2014

That will be a huge bike!

You have great fabrication skills

whereswally606 · Mar 22, 2014

Absolutely beautiful, subscribed

agniusm · Mar 23, 2014

Few more jobs done. Have cut out side panel, need to weld panels inside for various components as well as some flatbar for sidecover bolt holes. 1.5mm isn't too thick for threading

Got a chance to reassemble my 24s battery, now its 12x12 side by side. Here is photos of before and after:

Battery modules will be put in a heat shrink tube separately, then i will use glass fibre board and will put some pressure using industrial strapping tool and some plastic straps. I will incorporate fuse and BMS on the battery lid so i have 4 nice connectors for charging and discharging. I need yet to think of a tidy method to fix battery to the frame securely and with good access to bolt it.

I have an issue. I need to get Alex Rims DX32. You cant get it in Europe, Canada and USA only. Problem with Canada is rim costs 25 dollard and shipping is like 120. That's insane for 500g rim. Could someone check if it could bought and shipped cheaper and help me out on this?

agniusm · Mar 25, 2014

Have made series connection terminal that i was missing:

It aint gonna be lightest bike:

999zip999 · Mar 25, 2014

Great work and you do it fast. Will you be using a bms ? May need a temp sensor.

agniusm · Mar 26, 2014

Hi. Thanks. The progress is slow on my scale as there are many parts in transit for a month or longer. I have Eason smart LCD BMS but i will get another one. Somehow i dont like the idea of lots of bells and whistles on that BMS that might go wrong and limited discharge is another factor. The BMS i will use is quiet small, has 15A charge/aux discharge capability and unlimited main discharge with throttle cut off.
I am yet to think about temp sensor on the motor, but dont like the idea of attaching another LED display. I went for cheaper CA competitor and i think there is no function to display temps.
I am not so concerned about battery temps as i would need to pull 200A+ for 5-7mins to get them up to 55C and that wont happen before x5303 or controller blows.

agniusm · Mar 27, 2014

Made a stand, helping hand and foot

For scale:

Bench for TIG welding comfort:

Holder:

Cost me 10 bucks to build

SkyknightJohn · Mar 28, 2014

Looking good! I like the dual rail frame. I'm guessing it adds stiffness, which would be why many motorcycles do it. And I bet welding the square tubing is so much easier than the round!

agniusm · Mar 29, 2014

Yes, it is easier to weld. I think it will have enough stiffness. Aluminium box will add some as well.

silence · Mar 29, 2014

agniusm said:
I have an issue. I need to get Alex Rims DX32. You cant get it in Europe, Canada and USA only. Problem with Canada is rim costs 25 dollard and shipping is like 120. That's insane for 500g rim. Could someone check if it could bought and shipped cheaper and help me out on this?

What's the diameter and hole count You need?
Found a last? 26" 36 hole version from Poland and some different diameter but mostly 32 hole versions in Estonia. Not sure what the 19" from veloplus means. :roll:

2007blueprius · Mar 29, 2014

if you can find a deal in the states, check shipping online at usps.com, ups.com, fedex.com, dhl.com, whatever else you can think of, my zipcode is 48185 for example, if it make sense I'll relay it to you, also not sure about where you are from but sometimes people organise a container shipment, takes forever but its cheap

friendly1uk · Mar 29, 2014

There is a forum for things with no pedals. E-motorcycles. Some people might like to see this in there that wouldn't look in the e-bikes section.

Looks like your building a monster. Good luck with it.

agniusm · Mar 29, 2014

silence said:
What's the diameter and hole count You need?
Found a last? 26" 36 hole version from Poland and some different diameter but mostly 32 hole versions in Estonia. Not sure what the 19" from veloplus means.

I am looking for 20" rim.

2007blueprius said:
if you can find a deal in the states, check shipping online at usps.com, ups.com, fedex.com, dhl.com, whatever else you can think of, my zipcode is 48185 for example, if it make sense I'll relay it to you, also not sure about where you are from but sometimes people organise a container shipment, takes forever but its cheap

I have checked those and its expensive, I mean not worth it expensive.

friendly1uk said:
There is a forum for things with no pedals. E-motorcycles. Some people might like to see this in there that wouldn't look in the e-bikes section.

Looks like your building a monster. Good luck with it.

Yes, but most parts I use are actually bicycle parts. Dont know what kind of monstrosity the bike will have but I hope it will be moderate.
I have received x5303 after a very smoothe swap with ES member, spun it up and got 946rpm at 80V, 90.5kph unloaded for 20 inch rim. I am hoping to fit 16 inch michelin tyres so the diameter will increase slightly and I hope that in the end I will get 80kph top speed loaded.

agniusm · Mar 30, 2014

Here are some of the components i will use. 10A DC/DC, 5A charger and a fuse box:

Boght BMS. On the bottom part is 4 pin connector for controller logic disconnect. I get as much current i need and DC/DC coverter and charger will run of BMS output through FET's, 15A CH/DCH:

Have made battery faceplate, etching, photo paper and all

:

Here you can see 2 fuse holders. I will put one copper bar instead of a fuse, went with 2 just for the sake of symmetry and for tidy connections:

On the left there is 8 pin connector for charging, DC/DC, ignition switch and controller logic. BMS will be behind the faceplate, so only main connectors and 8 pin will be visible and accessible.

More to come...

agniusm · Mar 31, 2014

Took motor apart. Done some measuring. Any valid suggestions for most effective side cover hole pattern?

I will swap bearings to low friction skf while i am at it. The wires will be swapped for thicker ones, 8 gauge if i can.
[youtube]N7nTfl2Ot3E[/youtube]

agniusm · Apr 1, 2014

So I got rid of some aluminum:

Process:
[youtube]ZIH1jyxJscE[/youtube]

agniusm · Apr 1, 2014

Looking for paint for the stator and magnets. Seen here people using CRC red urethane varnish but reading up on specs revealed that it is good up to 100C. I found another one which is Silicone conformal coating form miller stephenson, K0805A
Dielectric strength 400V/mil
Operating temps -45C to 200C
Anyone knows where to get it?
Here is another one: MG Chemicals 419C

agniusm · Apr 13, 2014

Ok, so my motor is getting pimped at the professionals. 8awg wires will be fitted, coat of lacquer and new skf bearings. Still waiting on lots of components. The battery is nearly finished, need heatshrink to arrive, then weld aluminium box to allow some compression on the cells.

Have received my 2x120 radiator, pump and some fittings, still waiting on fans and some hose:

I thought of solution to make hydraulic brakes, e brakes. I hope it will turn out OEM look solution and will go step by step in dedicated thread but here are most components needed:

In the mean time I had to build a real tranquillizer gun for my brother for hes cattle

No pedals bike build blog (from scratch)

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