Build No. 2 - Reduction Drive - now w/ NEW video

[mauimart]

Here is the crash video. The only damage to the bike was a busted pedal.

[bzhwindtalker]

That thing seems to push! Apart form you wearing a hawaian shirt and no helmet, the crash was kinda lame haha, I crash like that 2-3 times per ride

[mauimart]

Some updates to the bike:

New set of Vuelta wheels with hubs for disk brakes.
Avid Elixir 3 hydraulic disc brakes.
SRAM X7 Shifter
SRAM X9 Derailleur
SRAM 9-speed cassette (11-34)
SRAM chain
Hinged battery box cover with magnet latching.

All that's missing now is a fork upgrade....

[mauimart]

Here's a new video shot entirely on my new RD32II ($119 US) in 1080P/30fsp. I'm quite satisfied with its performance thus far.



EDIT: Version that will play on mobile devices: http://www.youtube.com/watch?v=agWOH5dl9VQ

Here's how I mounted it to the bike. The v-brake bosses made for convenient attach points.

[mauimart]

With my recent upgrade of shifting components, I can now shift under WOT. Sounds a bit like an F1 car, at a lower frequency of course...

[h0tr0d]

How wide is your alu box?
And how that in terms of pedalling comfort?

Great build and vids!!

Congrats!

[mauimart]

.
The width of the battery box is right around 17cm (6.7 in). I made it that width to comfortably hold 3-wide of the Turnigy 6S 5000mAh packs. I do quite a bit of pedaling on this bike and have had no issues with the battery box getting in the way (no chafing). I did add a longer spindle (158mm IIRC) in the bottom bracket to allow for clearance between the crank and the reduction gears on the jack shaft.

I am currently in the process of upgrading to a 'real' suspension fork. Pictures when done...

[crossbreak]

nice bike and vids! the setup reminds me of my first build, which is disassembled cause it drew my bat empty in minutes . thanks for posting this stuff!

i hope your sprocket cassette holds up longer than mine. I used a shimano 9-speed cassette 32T-11T with shimano chain on my 1000W middrive test setup. It holded up for about 300km till the 11T sprocket started to slip. The 12T slipped followed 600km later, then I bought a 9-speed SRAM gear hub. It holds up well (about 1500km-2000km yet, my odo sadly was reset).

I hope you have an odometer on your bike. Could you be so keen to keep an eye on how many miles your cassette/chain survives under these circumstances? I plan for another bike with derailleur, that's why I ask. I plan to only use 13T and larger because of my bad experiences. Maybe your SRAM cassette is better quality?

I bought a RST Peak 130mm fork at the bay for 40 bucks a year ago, the oil damper of the forks works really sensitive and adjustable at a wide ratio. I'm very content about it, didn't expect that. It's a bit more heavy then the expensive forks but almost impossible to break. I can only recommend.

[pff7]

Love it, love it!!!! so nice----by the looks of it seems like it would pedal just like a regular bike w/o power? Excluding weight of motor, drivetrain,battery,ect. seems your freewheel would make the bike pedal just normally, am I right?

[mauimart]

i hope your sprocket cassette holds up longer than mine. I used a shimano 9-speed cassette 32T-11T with shimano chain on my 1000W middrive test setup. It holded up for about 300km till the 11T sprocket started to slip. The 12T slipped followed 600km later, then I bought a 9-speed SRAM gear hub. It holds up well (about 1500km-2000km yet, my odo sadly was reset).

I hope you have an odometer on your bike. Could you be so keen to keep an eye on how many miles your cassette/chain survives under these circumstances? I plan for another bike with derailleur, that's why I ask. I plan to only use 13T and larger because of my bad experiences. Maybe your SRAM cassette is better quality?

I actually worry more about the chain (crank to cassette) failing as it's not designed for these loads. Hopefully the SRAM cassette proves better than what you experienced with the shimano. Most of the time I try to keep the acceleration levels low so as not to over stress the already over stressed components. I always pedal first when starting. I also rarely use the 11T - only when doing speed runs and I need to exceed 45mph. Although none of these precautions has prevented me from getting 100A peaks on the CA.

I do keep records (dist, Ah, Whr, etc.) of each trip and I might post some data once I have a few more cycles on the bike. For the most part I am only keeping track of mileage when the bike is powered by the motor. My morning commute is all downhill so I don't even turn anything on, including the CA.

[mauimart]

Love it, love it!!!! so nice----by the looks of it seems like it would pedal just like a regular bike w/o power? Excluding weight of motor, drivetrain,battery,ect. seems your freewheel would make the bike pedal just normally, am I right?

Yes, the bike functions very close to a non-ebike with the biggest difference being the weight. It's 63 lbs now (down from 65 with the new fork ) which is 26 lbs more than what it weighed prior to conversion. There are two freewheels, one on the jackshaft and the other on the cassette so yes it does pedal normally and you don't have to pedal along with the motor if you choose not to. And I do pedal quite a bit. For example a recent ride went like this:

35.7 mi
6.17 Ah
430 Wh
12 Wh/mi
16.9 avg. sp.
2hr6min

[h0tr0d]

.
Are your wh/mi correct? if so, amazing figure!!!

Is your turnigy "stock" or heavily modded?

Love it, love it!!!! so nice----by the looks of it seems like it would pedal just like a regular bike w/o power? Excluding weight of motor, drivetrain,battery,ect. seems your freewheel would make the bike pedal just normally, am I right?

Yes, the bike functions very close to a non-ebike with the biggest difference being the weight. It's 63 lbs now (down from 65 with the new fork ) which is 26 lbs more than what it weighed prior to conversion. There are two freewheels, one on the jackshaft and the other on the cassette so yes it does pedal normally and you don't have to pedal along with the motor if you choose not to. And I do pedal quite a bit. For example a recent ride went like this:

35.7 mi
6.17 Ah
430 Wh
12 Wh/mi
16.9 avg. sp.
2hr6min

[pff7]

But when you pedal w/o using motor, in other words with no throttle, when pedaling are you turning the motor or is the motor turning via drive chain when you pedal? When your applying throttle I assume freewheel let's you keep feet on pedals without turning, but does it work vice versa? And if motor turns via only pedal power I'm assuming from what you stated that the motor turns very easily then.

Love it, love it!!!! so nice----by the looks of it seems like it would pedal just like a regular bike w/o power? Excluding weight of motor, drivetrain,battery,ect. seems your freewheel would make the bike pedal just normally, am I right?

Yes, the bike functions very close to a non-ebike with the biggest difference being the weight. It's 63 lbs now (down from 65 with the new fork ) which is 26 lbs more than what it weighed prior to conversion. There are two freewheels, one on the jackshaft and the other on the cassette so yes it does pedal normally and you don't have to pedal along with the motor if you choose not to. And I do pedal quite a bit. For example a recent ride went like this:

35.7 mi
6.17 Ah
430 Wh
12 Wh/mi
16.9 avg. sp.
2hr6min

[mauimart]

.
Are your wh/mi correct? if so, amazing figure!!!

Is your turnigy "stock" or heavily modded?

The Wh/mi figure is accurate as I pedaled a significant amount. The motor was rewound with 9T #14 AWG in wye configuration and bearings were replaced at least twice now.

But when you pedal w/o using motor, in other words with no throttle, when pedaling are you turning the motor or is the motor turning via drive chain when you pedal? When your applying throttle I assume freewheel let's you keep feet on pedals without turning, but does it work vice versa? And if motor turns via only pedal power I'm assuming from what you stated that the motor turns very easily then.

The pedals will not drive the motor as there is a freewheel on the side of the jack shaft that drives the crank. And yes the motor does not cause the pedals to turn as there is a freewheel in the spindle assembly. The drawback of 3 freewheels in the drive system is that there is quite a bit of play or slack between the motor and wheel. Not a huge issue but definitely noticeable.

Here is a video of the aforementioned ride. It's over 2 hours compressed into 8 minutes.

[Byte]

The gear shifting is awesome!

[Warren]

Martin,

Your BB drive, MTB is spot on. Now tell us about the Manta!

http://www.youtube.com/watch?v=4H_6brrN ... ature=plcp

Warren

[mauimart]

Martin,

Your BB drive, MTB is spot on. Now tell us about the Manta!

http://www.youtube.com/watch?v=4H_6brrN ... ature=plcp

Warren

More info here:

viewtopic.php?f=34&t=37911
https://sites.google.com/site/seaburyha ... ectric-car

[Warren]

Martin,

Thanks for the links. Probably need a wider front track for a three wheeler. I can't believe somebody hasn't yet successfully marketed an EV trike similar to this. Polaris now owns GEM. With 12 kWh pack, 30 hp, under 1000 pounds it would be a fun all weather commuter.

Warren

[mauimart]

Just rigged-up a prototype rpm bar graph that may find its way on the bike. I will replace the Arduino with LM2907 (frequency to voltage converter) once it arrives. This will make those rapid gear changes more dramatic.

[sn0wchyld]

Just rigged-up a prototype rpm bar graph that may find its way on the bike. I will replace the Arduino with LM2907 (frequency to voltage converter) once it arrives. This will make those rapid gear changes more dramatic.

ha! awesome mate.

[crossbreak]

Nice rev counter! Now try geting it on your bike I have so much calbe on my bike, it makes most of the weight i guess lol. I hope the counter will work in your case, once used a similar one to count "sines" but it didn't I hope you have more luck. The speedict could do the job also, if it would measure phase currents, but it doesn't

[Byte]

That RPM thingy is awesome! Where can I buy one?

[pff7]

Can't find the 80-100 motor outrunner on HK, do they not have it anymore? and if not what would be equevalent?

Awesome video, being in fast motion was hard to tell how fast you were going though......and did you do the whole 2 hours without a recharge? I noticed some of those roads not having a shoulder really...but the scenery was very good.

Ive always thought using the existing drive train on the bike seems most efficient and smart.

[mauimart]

Can't find the 80-100 motor outrunner on HK, do they not have it anymore? and if not what would be equevalent?

Awesome video, being in fast motion was hard to tell how fast you were going though......and did you do the whole 2 hours without a recharge? I noticed some of those roads not having a shoulder really...but the scenery was very good.

Ive always thought using the existing drive train on the bike seems most efficient and smart.

The 80100 motors seem to available at Leaders Hobby (http://www.leaderhobby.com/product.asp?ID=9394001224162).

With regards to the video, I did pedal a lot and my average speed was about 17mph. The only time I really 'opened it up' was after being passed by the car (8:21 in video) where I did 40-45mph for a brief stint.

[pff7]

Cool.....I bet at 17mph you got way more distance with your batteries.And the pedaling helped too....I also like pedaling my power-assisted bikes , wouldn't have it any other way.(I have gas also)

Thankyou for the link...not a bad price comparing to the greyborg.The specs I believe say power=6500 Watts. But you mentioned the bearings not being to good though.....very good thead.