Custom Build... 2 Speed H.O.B.O Powered e-Cruiser

[AussieJester]

Sorry to those wanting to see some flash carbon fiber (CF) i had all intentions
to do the side panels in CF, until i started playing with carboard templates
and grew to like the simplistic look that still allowed a peak
below to see the CF panel and mounting hardware, gear lever mechanism and ThudSTeR
2 Speed... So, after 4 different templates were cut over the last week and a half, i decided
on this design-->


This is 2mm alumnium sheet, i covered the outer facing side with masking tape
to protect it from scratching, and to make marking out the template's shape easier..


As i said to RodGaH, i had these :: cough:: "Lazer cut" i.e 6in angle grinder and a cut off disk





I had actually lined up with a mate to use his works bender to do the bending, but seeing it
was only 2mm, i ran the angle grinder along the reverse side of the 'bend line'
prior to clamping the ali between two pieces of wood in the vice and heaving on it...resulted
in a very neat crisp bend...then, the best moment of it all, removing the masking tape!


And no, the ali will not be remaing in its natural state one of three things will happen
it will either be painted the colour of the frame, the side panels used down the track
as a mold and/or plugs to make the exact thing from CF, OR they will be anodised along
with the remaining ali pieces...not sure yet OH, intrim i may fake it up with
some of the vinyl CY contact same as we have seen Matt.P use on the last 3 bikes
he put together, very resilient and looks the part..and at the very least will give me a
better indication if i would like them in 'real' CF... :: shrugs::


I bolted both of the panels together after cutting them and prior to bending, to 'match them' up
at least where they were both the same, the motor/drive ends of the panels differ slightly
i decided in case of a chain snapping (has happened to me before on motorcycles) i
would have a little 'insurance' against the flailing chain taking out the electronics-->







^^ would like to 'angle in' the lower section of this panel same as the other side but there is a
plastic project box directly behind it containg alot of wiring/connections so straight
it must be, the chain clearance is ~5mm..the other side however turned out nicely in respect to
directing air over the Castle Creation HV160-->



theres ~5mm clearance from side panel and the HV160 ESC, should get some nice
air flow directed right over the heatsink!...the Turnigy motor is thus left out in the breeze
also, to suck in the cooling breezezzz

I was concerned about the bus bars/connections being easily poked and proded the
angling in of the top of the panel nicely covers the connectors, will disperse light rain if ever caught out
BUT still leaves the aluminum angle with its lightening holes, visible...-->



looks neat i think and yes haha Hal, if your reading this, there will be some lightening holes added
to these panels, a row at least matching the ones on the angle will be done along the very top
of the panel...As can be seen the front of the panel is bent inwards
hopefully help a lil in the aero department?



With alot of the stainless steel fixtures still visible, i am keen to place an order at ProBolt
for some blue anodized alumnium cap screws and nuts to replace the stainless steel bolts/nuts
used now, not so much a weigh tthing as a 'wank factor' thing though i admit...

Shall keep those still reading the worklog updated for now i'm off for a ride

KiM

p.s 1.15PM today! i take ownership of my new WHEELCHAIR!!! 5k worth of the latest Quickie
chair from America! C9omplete with Synergy wheels (they cost ME $AU850 though ::sigh::)
I have the Aussie Tax payers to thank for the chair though hehe hrmz...5k for a freakin
wheelchair frame has less then 200 bucks of aluminum in it...

Looks very tidy mate. Nice clean work as per the usual high standard

Resourseful and clever use of the angle grinder and wood bending those plates, came up very sharp.

I likey

Cheers my D-MaN from NorthBridGE you will getz to see it in person Saturday maybe
new gearing on her and your light frame i think you will have a nice EV-Grin when you
return from a blat hehe...incentive to get up here if we have the time can swap in the ThudSTeR
wound Turnigy see how much quicker and harder that is on the HV160
IIRC its got ~150Kv ...20kv higher than stock Turnigy...

Maybe with how solid it has been, people will start to believe that RC setups are just as reliable as frocks if you aren't pushing there limits. Which many of us already know.
Clay

Cheers my American/KiwI Monkey MaN Yeah RC setups can be hella reliable
if you just want a commuter with a bit of oomph now and again, its when you push their
max limits constantly, their reliability becomes an issue...tame them down
to ~6kw peaks and they do well...thus far and they iz still alot of fun...
Richard asked me to accelerate to 50km/hr on the ride we went on last Friday
he was quite impressed by the acceleration, and i didnt have to change gear LoL...
So while more reliable it still has some get up and go!

The bike looks great, and sounds like the performance is giving you a great deal of pleasure. I do have a question though, do you think the infineon controllers would hang together now if you used the cycle analyst to control the current the same way as you have done with the CC HV160 ? Keep up the good work I always look forward to updates to your thread .

Cheers matey and Yes & No ... not on a 50v setup the Infineon is poo IMO
i would/have blown a 12 fet not far out the driveway...Up it to 60v setup
and it has been shown by a couple that have raced these setups that they are close
to HV160 performance and alot more reliable
long as you dont cane the utter shit out of them constantly... Paul D got
first place in the Death Race using Turnigy motor and infineon controller running high voltage...


Cheers for the positive feedback fellas always appreciated, motivates one
to keep on going when boredom sets in LOL

KiM

p.s have my new wheelchair it is THE SHiT!!! sooooo light
and i want these wheels/rims/hubs on an ebike...D-MaN i think we
found the right hubs for the Cross 4 build
I'll start saving, since we will need 4 of the f*ckers LoL
I think GeeoOOF will have trouble matching the colour
of this chair for the frame though has that colour changing chameleon
thing goin' on hehe

[Danny Mayes]

found the right hubs for the Cross 4 build

Can't wait to have an ogle

i was wondering if you were going to go for a colour match He sure will...

[AussieJester]

found the right hubs for the Cross 4 build

Can't wait to have an ogle

i was wondering if you were going to go for a colour match He sure will...

I just went out and took a few pics of the chair Danny, the camera
actually pics up the colours well, although at a glance it looks like
metallic blue, then when you look closer you see the other flecks
of colour in it...

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I honestly thought of Luke when i ordered the single sided fork, know how much he LOVES
single sided forks and swing arms on motorcycles....not

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Very very very happy with it, i thought i might miss the old Quickie XTR
with the suspension, missed it for about a second, the time it took
to transfer from it to new chair...

Might Cya Saturday D-MaN

KiM

[gtadmin]

Hi AJ, looking good mate

If you were asking for input on what to do with the side covers, ++anodising for mine. On your 'chair, as a taxpayer I don't mind chipping in to help out my fellow aussies so I'm glad you like it and it fits your needs. But chameleon paint, hmmm - perhaps I've seen to many crappy Commodores painted with it but ... everyone to their own I guess

Cheers,
GT

[Ypedal]

Nice chair man !!.. ( insane prices for the materials involved.. but it's certainly well done with plenty of details !! ) cool rear hubs with straight spokes, i wonder if they do these for bicycle components ?

[Hyena]

Yeah nice new wheels but DAMN, that's bloody pricey for what it is! The seat looks pretty budget for a 5k wheelchair, I'd atleast expect a fancy full grain leather job for that
I see your forks already have lightening holes

The battery covers look good. Any reason you left the top front corners so open ? I guess it was either that or make it more of a square box, which would probably look out of place

[Philistine]

Geez Kim, even your wheelchair is pimped out.....

The side covers on the bike look fantastic, stunning looking bike, must seriously turn some heads.

[nicobie]

I didn't think you could get the bike to look better than it already did. I was wrong.

I vote for the imit. CF. I did that on mine and am happy with the look. Sometimes too much anodizing or bright alum/SS is a bit much for me. But different spokes for different folks...

Re: the paint A few years back we left the frame bare on the desert race car, just applied liberal amounts of WD-40. Sure made it easy when the frame got bashed and had to be fixed.

[liveforphysics]

That looks like a hell of a chair mate. But you need to put the other side on your front wheels! LOL Just think of all the weight you could save (<5g ) and the increased rigidity if you went to a double sided fork arm.

Those wheels are tits. That's a nice setup.

[Danny Mayes]

The chair is very nice bro, esp those wheels and hubs.

Just got back from the Mundaring Weir Hotel. 16.2 k from the roundabout.

That place is interesting. We got attacked by birds. I was wondering why the native birds looked so haggared. They come right up to the table. I offered one some lettuce and it was very non interested. Then i offered it a greasy chip, that was when the other birds attacked. They look so haggared cause they only eat chips.

Wrong

D

[numberonebikeslover]

Hello my dear friend,

I have been following your built from the beginning and it certainly has been my great inspiration. Your bike has come out very nice. May God give you ever success.

Respectfully
Naeem

[recumpence]

Hey Kim,

That chair is freaking awesome!

It is screaming for some brushless/lipo setup!

Oh, hey, I can get Industry Nine wheels at cost for your next project (needing four of them). I can get them in 26 or 20 inch.

I will be ordering a freaking WICKED set of black rims and hubs with red spokes 20 inch set for my Cannondale soon.

Matt

[AussieJester]

Cheers fellas, great to hear from you Naeem hope all is well in India? Thankyou Mr Recumpence SiR! shall
be in touch if Danny_Mayes and I ever get to building the cross 4 replica

So i went for a ride on Mondee with ES forum memeber Jehu (Richard) just a short 12km hike to the backery
in Kalamunda for some breakfast before we started work on his Stealth Fighter replica frame Long story
short i was showing off in the gravel, doing ~10km/hr i nailed the throttle the back wheel spun up on the loose
gravel then hooked up on the damper stuff underneath, the bike took off like a startled Gazelle!... then SNAP!
and no forward mojo I wasn't sure then exactly what i had broke, i assumed a chain as second gear was working fine
so Richard and I continued our ride...When i got home i popped the cover off the gearbox to see a chain hanging there GOOD
were my first thoughts i have meters of #25 chain i can fix this sucker!

The issue with the chain was it was very slack, not quite enough to take the link and a half of chain out
and there was no idler or tensioner on the first gear chain, ThudSTeR fitted a polyethelene idler
to the second gear chain and its fine, sooo...i added another polyethelene tensioner to the
chain and BOY what a difference it has made! There is no more clattery sounds coming from the box
its just smooth and very very very quiet, i can't hear any chain noise whatsoever after 10-15km/hr...and very little below

I attempted to take a video of the imporovement but failed miserably, i have covered every freakin
hole i can see on this camera Kurt kindly donated to me with Durex tape
but damned if i can get rid of the bloody wind noise! I added vibrating tape to it as well this time hahahaaaa
thought iwould post the video anywayz If you listen carefully in parts of the video you can hear the motor
and box and how much quieter it is, its a different bike to ride it really is! I didn't think i could be more
impressed with the ThudSTeR BoX but i am!!!



I have also decided to swcrap this frame in favour of making a replica in chromo 4130 I have been
talking with Thud and he has kindly agreed to pick up a roller bender from Harbour and Freight
box it up and send it too me, its hundreds and hundreds cheaper than any roller bender i can get local...
With this i can get me some niiiiiice smooooth bends no krinkles like the pipe bender i have used
in the past creates.. I will have the spare $$$ in a fortnight to fix up ThudSteR for this...

I have also bought another Turnigy motor a CA-120 from ES member Timma2500 that
Thud again has kindly agreed to give me instruction on rewinding, unsure how what or where
this will be mounted on at this time, i am hoping on the chromo bike if there is enough room for it
and the two speed!

Anywayz...heres a few blurry snaps of the work i did on the box, nothing exciting but for the case of
documenting it all here they iz...



Sorry about the blurry pic the camera dont do close ups to well im afraid



I used a polyethylene 'wheel' i had cut with a hole saw for the stabilizers for the tensioner
lil shaping and it was good to go, drilled and tapped a small 2.3mm hole to fasten it to the side of
the box as ThudSTeR had done with the second gear tensioner...

Think thats about it for now... Helping Richard make a monocoque stylin frame will be a worklog
on that soon the designing is done Richard should be getting the plates cut any day...

ciao for now peepz...

KiM

[Ypedal]

at a certain speed that mic makes the thing sound like a balouga whale in heat.. wooowoowoooowoWOOOO... lmao..

running good tho.. awsome. if your CA wont stay put, build up a thick ring of electrical tape on the bars and ditch the layers of rubber spacers, you can then crank it down and it stays put.

I have to get myself a can of mx lube for that darn 2nd stage chain, i canot get any other lube to remain on the damn thing .. she spins so fast it flings off within 5 minutes... a real pisser too cuz it runs ways mooth and nice when oiled up proper.

[Hillhater]

I have to get myself a can of mx lube for that darn 2nd stage chain, i canot get any other lube to remain on the damn thing .. she spins so fast it flings off within 5 minutes... a real pisser too cuz it runs ways mooth and nice when oiled up proper.

Those chains are running much faster than any moto chain ever goes, so you need some real sticky lube to stay on,
Take a lesson from the Kart racers whose 219 chains really take a beating at 15-20k rpm !
Try Motul Factory Line or Bel Ray chain wax.

[AussieJester]

Belray chain lube (seen in above pic) is what I use on the 2 speed chains
Sprays on liquid like, then you leave it for 10 minutes
Before using bike, the lube changes to a wax-like consistancy
Tiz brilliant stuff, never comes off and collects minimal
Dirt...

Electrical tape wraped around to keep CA on
Reeeally, Gaston Neoprene rubber cut into strip and wrapped around bars works for me...oh, my CA is fine BTW I was simply trying
To get it on an angle the camera could pick up the info.

KiM

[mauimart]

Nice pass of car at 2:55 in video . The school children must have been impressed...

[Kurt]

One idea on the crappy mic on that camera. I cant remember but I think you can plug a external mic into it. Perhaps if you have a cheap headset for a pc. You could then stuff this in your shirt and cut out the wind noise.

Ps, You need a electric slide on your garage door. I went for a spin around the block with my garage door wide open once just so I could roll on in when I returned. I was thinking its Just for 5 min. I was just testing my car around the block. Some pri** took things out of my garage while I was gone.

Kurt

[AussieJester]

Nice pass of car at 2:55 in video . The school children must have been impressed...

HAHA yeah lil dangerous but....there was ample room

@Kurt...Yes there is indeed a spot for external mic i will try that i have a few pc mics about the place ill dig one up from the parts bin IF my other plan doesn't work LoL...i thought i would rip an old t-shirt up, and wrap the crap out of the camera with it leaving only the lens protruding! will look a site strapped to the side of my head but it should cut the wind noise out...its got me stuffed which opening is the mic though, i have put duct tape over them before and still wind noise occurs...Will try again this arvo anywayz, i really want to capture better audio with realistic sound levels, everything i have done and heard is way louder on camera than IRL...

...just got off the phone to Richard he has the side plates of the frame cut and is heading up to y place i'm going to tack it all together on my frame jig ready for him to take to work and weld up (he works as welder) Spoke with Timmaa2500 catching up with him Mondee arvo to pay and collect a Turnigy CA-120 never used, looking forward to rewinding and halving a play with this on the bench, with ThudSTaRs GoD-LiKE guidance it should be pretty plain sailing...i hope LoL..

ciao for now guyz OH

KiM

[AussieJester]

Got me a new motor last night when good ol Timma2500
dropped over I iz now the proud owner of a Turnigy CA-120

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^^ Sitting next to a ThudSTeR rewound V1 Turnigy 80-100 130Kv motor
She is a big bastard ain't she Will be rewinding this one ala Thuds
instructions, then have to squeeze it onto the bike somhow... wanna see new frame anyone?

Thanks again paul, i shall build a good home for this Mofo H.O.B.O

KiM

[johnrobholmes]

Holey smokes that is a big "toy" motor!

[Hillhater]

do you have a plan for a suitable controller /smoke generator ??

[AussieJester]

do you have a plan for a suitable controller /smoke generator ??

Thuds uses a modded 12fet infineon with 66v setup to run his CA-120...I shall be doing the same.

KiM

[Kurt]

do you have a plan for a suitable controller /smoke generator ??

Perhaps this little $10 beauty would be fit for the task. although it could be overkill as Its good for 5A burst for 3 seconds Hey at least when you smoke it you wouldn't be to disappointed LOL





Looks like a beast of a motor there AJ you should be able to fit a good chunk of copper in there. Keen to see how it all turns out.

Kurt

[etard]

Those are beautiful motors, a little too open for the elements of an ebike for my taste, but as long as you put a guard on it you should be good! Well that is, until the controller blows. Speaking of, why can't these just be run with a HV160?