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

[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

FILE0084.jpg (99.46 KiB) Viewed 500 times

^^ 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?

[AussieJester]

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?

Prolly can, i believe stock they have an incrediably high no load speed up near 17amp IIRC
I don't know anything about the rewinded motors, awaiting ThudSTeRs instructions
he also has a bulk order of wire coming for rewinding motors, i'll be purchasing some
of it for this motor along with some notes on rewinding, i'm in no rush so don't expect
any updates anytime soon, I have organised the roller bender thanks to Thud he is going
to grab it and try it out i'll have cash for freight in a few weeks, will get the bender through
along with wire and instructions for the rewind i think...
I am looking forward to rewinding the motor, by all accounts it is a goer with alot
more power than a couple of 80-100 130kv Turnigys ..I be needing something to kep in front
of some of the locals building bikes with more powerz than the 2 speed cruiser...riiight Danny_Mayes

KiM

[DALBYNATOR]

Hiya AJ,

That is one helluva motor May I ask why you are rewinding it? Lower Kv I'm guessing?

I guess with that beauty you won't be needing the old 80-100 anymore
If not, I would love to take it off your hands for a reasonable price.
It might give you some more funds for another one of your beautiful frames.

Toss me a PM if you're interested anyways.

Cheers, Tom.

[mauimart]

Nice motor. If you are up for some additional info regarding rewinding this monster check out the following rc groups thread starting on page 3, post #43.

http://www.rcgroups.com/forums/showthread.php?t=1412424&page=3

[gtadmin]

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

FILE0084.jpg

^^ 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?
...

Yes please Err, is that speed holes in your mouse? That's taking it too far AJ

[sico]

That's a monster Kim, can't wait to see the new HOBO project begin.

Is there a drive shaft on the mounting side of the motor or do you have to drive off the can?

[Fizban]

Thats one hell of a motor you have there. I think you might have to register whatever bike you build to make a home for that beast. Might I suggest using a 4 speed gearbox from a pre-unit royal enfield for the gearbox to go with that monster, they are built to cope with 25hp 500cc ICE motors. Then again having the new wheelchair come off the towhitch at 120+kph might not be good. I like a lot of other loyal followers of your inspiring work will be keen to see what you come up with. Keep up the good work and keep having fun.

[bigmoose]

So it doesn't get lost, this from post 103 in the Lazair reference:

Upon inspection after the last flight, I noticed what appeared to be solder spray that had landed on some stator windings of both motors. After disassembling both motors I found that the Y node of the WYE wound motor windings had overheated and the solder from the node had melted and migrated out, onto the windings. Although the node was still mechanically sound because I had wrapped the joint with fine stands of wire while I was soldering it, the overheated joint was a likely source of additional heating. I was lucky that the joint did not completely fail and destroy my motor controller again.

In hindsight I should not have buried this soldered Y node deep inside the motor windings, the hottest section of the motor. Currently I am beginning the rewinding process on both motors again but this significant delay in testing has forced me to cancel my cross country plans. I still hope to be able to fly the plane at Oshkosh.

Needless to say, I will terminate all 6 of the winding ends outside the stator area this time.

[AussieJester]

That is one helluva motor May I ask why you are rewinding it? Lower Kv I'm guessing?
I guess with that beauty you won't be needing the old 80-100 anymore
If not, I would love to take it off your hands for a reasonable price.
It might give you some more funds for another one of your beautiful frames.

Yup lower Kv ...and no on the Turnigy 80-100 sale i am actually in search of more myself
i have only the one pictured and the one on the cruiser i would like to purchase at least 2 more of the
V2 motor...would actually like one of the V1s also they sound so much nicer at full noise...

Nice motor. If you are up for some additional info regarding rewinding this monster check out the following rc groups thread starting on page 3, post #43.

http://www.rcgroups.com/forums/showthread.php?t=1412424&page=3

Thankyou for the link mate, very nice ultralight he's electrified, i saved a few pics and will
make a post in another section of the forum highlighting his use of Lipo for all the
e-bike lipo users scared shitless of their packs on the bike...

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

FILE0084.jpg

^^ 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?
...

Yes please Err, is that speed holes in your mouse? That's taking it too far AJ

HAHA nagh no 'lightening holes' on the mouse, thats how it came i think its meant
to look like a stone or a rock...my friend bougyht a couple of them on special and gave me one of them
very nice mouse..

That's a monster Kim, can't wait to see the new HOBO project begin.

Is there a drive shaft on the mounting side of the motor or do you have to drive off the can?

Yup appears to be a drive shaft on it but the sprocket/prop attaches to the can also, go kart sprockets would bolt onto these beautifully...

Thats one hell of a motor you have there. I think you might have to register whatever bike you build to make a home for that beast. Might I suggest using a 4 speed gearbox from a pre-unit royal enfield for the gearbox to go with that monster, they are built to cope with 25hp 500cc ICE motors. Then again having the new wheelchair come off the towhitch at 120+kph might not be good. I like a lot of other loyal followers of your inspiring work will be keen to see what you come up with. Keep up the good work and keep having fun.

Yup its a beast ain't it haha...only gearbox that would be used on this would be a ThudSTeR 2 speed i also
have no interest whatsoever of going over 100km/hr on a bicycle, high speeds don't impress/interest me one iota
~80km is fast enough, long as it has the power to get most of the way there with the front wheel
2 inches off the ground...

So it doesn't get lost, this from post 103 in the Lazair reference:

Upon inspection after the last flight, I noticed what appeared to be solder spray that had landed on some stator windings of both motors. After disassembling both motors I found that the Y node of the WYE wound motor windings had overheated and the solder from the node had melted and migrated out, onto the windings. Although the node was still mechanically sound because I had wrapped the joint with fine stands of wire while I was soldering it, the overheated joint was a likely source of additional heating. I was lucky that the joint did not completely fail and destroy my motor controller again.

In hindsight I should not have buried this soldered Y node deep inside the motor windings, the hottest section of the motor. Currently I am beginning the rewinding process on both motors again but this significant delay in testing has forced me to cancel my cross country plans. I still hope to be able to fly the plane at Oshkosh.

Needless to say, I will terminate all 6 of the winding ends outside the stator area this time.

I have had a bit of a read through that thread late last night BiGMooSE i spotted that
issue also I see he has moved to a couple of Joby motors now the Turnigys a little underpowered for
the high constant power he required... hrmz...i wonder if i could pick up the Turnigys cheap

Cheers all for the interest, shall create a new thread when i start rewinding this and building a frame to mount her in...
or modify the existing one, seeing it will be trashed anywayz in favor of a replica chromo replacement...

ciao for now...

KiM

[dbaker]

What an aircraft I loved the lipo bricks hanging from the wings

[markobetti]

i look forward to you build ( read : documented with a lot of juicy pics) with this motor. Your setup is going to fly with this motor , i am quite happy with its performance.. that i have seen by now... Aussie , if you will add external hall sensors pm me so i can send you the setup for them that i have

[AussieJester]

i look forward to you build ( read : documented with a lot of juicy pics) with this motor.

Well buddy, that time is alot closer to happening, i just got back from forking out
$AU235 for enough 4130 chromo to build a new frame, a replica of the current frame minus
the kinked tubing as ThudSTeR hooked me up with a new roller bender from Harbor Freight he 'da MaN!

re: the Chromo tubing for the new build, front half i have gone with 1.5 x .035inch tubing which is ~38mm the current
frame has 32mm 1.2mm wall thickness tube, the weight difference is UNBELIEVABLE the chromo
tube is thiner and wider but SOOOOO much lighter...and of course stronger, the slightly larger diameter should give the bike
a bit of a chunky look...i hope ...in contrast For the rear chain and seat stays i have downsized slightly
i have gone with 19mm wide tubing with (.5mm wall thickness IIRC )
Its slightly thinner diameter however, we are Down from the 23mm diameter i used on original mild steel frame
Thicker than the 38mm tube wall thickness anywayz need the extra strength to stop the flexing... RAPT
with the supplier of the tubing Go Gear Racing The have HEAPS of sizes and
shape tubing, one in particular caught my eye, its 'aero' tubing
cross profile of it looks like a symetric aireoplane wing, had images of frames using this rushing through my head
when i was at the shop, the fella that served use was excellent, said he has had alot of fellas in buying chromo
for custom motorcyle frames, wheelchairs and even aeroplanes! I seriously think a tow able chromo wheelchair is in order
i can't keep using my new chair the tread on the tires is nearly gone and its only a month old :-S

Shall prolly start a separate worklog when i do this new frame? Will do this when the bender arrives OH ShiT! i also need another
suitable head tube..ARGH...off to order one now... i.e Ring Matt.P see if he can hook me up......yet again

ciao for now gents..

KiM

EDiT: p.s i also bought half a sheet of flat plate chromo 4130 for gussets, unfortunately they only went to 3mm which IMHO is
too thin for rear dropouts, so they will again be the 5mm variety as per used on original frame

[sico]

Hi mate, I'll be following this one with interest.

Do you need special wire to weld (or get full strength from) the chrome molly?

Does the pipe need any special treatment before or after bending?

Cheers,

Simon.

[AussieJester]

Hi mate, I'll be following this one with interest.

Do you need special wire to weld (or get full strength from) the chrome molly?

Does the pipe need any special treatment before or after bending?

Cheers,

Simon.

No special wire needed to weld it i have been told, unsure if there is MiG wire available specifically for chromo?
And Jeremy Harris posted here on ES that thin chromo tubing doesn't require any special heat treatment...I
think IIRC Jermey said its when you start getting alot thicker and large sections of welding on
chromo, heat treating is required to get full strength back, but i could be wrong on that..?Luke? input? maybe LoL
either way this frame will be welded with the wire i have and not heat treated any further than maybe using
the propane setup to heat the welded areas a little, the entire frame heat treating scenario wont be happening guaranteed ...
...Hope you enjoy the build anywayz, i was hoping to get it as close to the current frame as i can, i still have the image of it
drawn on my garage floor when i fabricated it so can re-use this as a guide I have also
though, been thinking of 'wayz' to include a few inches of rear suspension without distracting too much from
the flowing lines of the frame...basically gotta look good first and performance second ....i have two sketches
one where the shock runs along the bottom tube (where the actuator is now) and requires a more tressel
type swing arm, which i LOVE but alas due to shock postion and actuator in the way, well...... where as the second
(which will likely be used if i go with rear suspension) the shock sits below and parallel to the top tube lil forward
of the seat tube...Only need a few inches of travel for a street going bike..imo

KiM

[Grinhill]

I'm looking forward to seeing the CroMo version of your cruiser, Kim, get welding soon!!! How much lighter do you think the frame will end up?

I suppose you have considered a trailer or trolley arrangement for your wheelchair to keep the main wheels off the ground? What about some pneumatic pram wheels, like the ones that are about 200mm diameter?

[recumpence]

Kim,

Chromo is a friggin @#$%*& to cut, but it is easy to weld. DO NOT QUENCH THE WELD! It gets brittle. Just let it cool slowly. In fact, I have been told some guys will insulate the weld in various ways to let it cool really slowly. I think that may be a bot over the top, though. I just weld it and leave it. No problem.

Matt