Tom's BEAST

[bobc]

Just got the parts from the laser place, didn't get the price yet as the man who deals with that wasn't there.....
One of the keeper plates has moved a fraction (about 1mm) during the process - first time I've seen that happen - it's usable as is, maybe better if attended to with a file... I'll mark it so you can decide what to do. I'll fettle the teeth tonight & post it tomorrow.
I'd post a picture but it looks just like a nicer version of the CAD file above...... ;^)

[lostrack]

Just got the parts from the laser place, didn't get the price yet as the man who deals with that wasn't there.....
One of the keeper plates has moved a fraction (about 1mm) during the process - first time I've seen that happen - it's usable as is, maybe better if attended to with a file... I'll mark it so you can decide what to do. I'll fettle the teeth tonight & post it tomorrow.
I'd post a picture but it looks just like a nicer version of the CAD file above...... ;^)

Awesome, can't wait. It's like Christmas!
Are the plates not symmetrical, you mean? I've filed Alu before, can't imagine steeel will be easy... maybe worth a trip down to the ironmongers who have a lathe?

[bobc]

nah it's just as though the 4mm bolt holes have shifted a touch. It bolts up OK & exact position of the keeper plates isn't any sort of issue so I don't think you'll have any trouble. I'll assemble it OK for 1/4" chain & you can adjust to taste (+ maybe you'll want to use stainless screws & nylocs ;^)
It's in a box ready to go now - PM me your address, urgent (I'm away on business for 2 days as of tomorrow)
PS - it might work OK without the keeper plates - would be quieter and lighter - if you want to try it....?

[steveboc]

Hello Tom, I want to buy a bike like yours, where can I buy one?

[Idontwanttopedal]

Pinkbike

[Green Machine]

Be looking forward to this new carbon update...subscribed..

[lostrack]

A few updates..

New rear sprocket (*THANKS!* designed by BobC) and new carbon batt box. The box isn't together yet as due to a manufacturing underestimate...the pedals don't clear it!

Got some Gustav M brakes, they need a bit of tuning in but feel quite beefy.

I will have to get a new BB and cranks. Might consider some freewheel crank action...

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...yes, the battery box clears the sus @ full travel.

...yes, it looks loose (because it's not attached yet)

[bobc]

Looks cool Tom - have you run it yet? chain run OK? any tendency to skip/fall off?

[lostrack]

Looks cool Tom - have you run it yet? chain run OK? any tendency to skip/fall off?

I'm having trouble with the carbon box I made - it grew in the mould slightly and there's not enough clearance to pedal. I'm already running one of the biggest BB's in existence (100mm shell, 143mm spindle). Right now I have to think my way out of this until I can ride it

I think you can get 153mm BB's (which would clear it) but the shell is only 68mm so it would hide inside the frame hugely...might not even screw in.

Any ideas?

[knoxie]

footpegs? ha no seriously maybe you could get some extension pieces made for the bottom bracket? is it a std old spec spline or the new type, you can get 2 piece bottom brackets that screw together on the inside i.e they dont even use the threads in the frame, they may do them at that length? I will see if I can find where I got mine from I used one on my Proflex as the threads in the frame were shot, nice work on the carbon box btw



http://www.sjscycles.co.uk/prestine-threadless-68mm-sealed-bearing-bottom-bracket-for-frames-with-damaged-threads-prod16505/

You could get one of these, they will clamp up to 110mm you could then take the shaft out of it cut it in the middle and extend it or maybe see if a std taper axle would fit in there? maybe weld a lump in the middle or drill 1 normal 1 reversed thread in either end, although considering the jumps you do it may be safer to make a new battery box

[Green Machine]

You can have phil woods custom make an even wider bb.

The only problem is phil woods bbs are a little pricey (close t0 200 shipped) but the best bb's in the bike business.

Contact them and give it a try.

Alternatively you can go with the square taper 100mm bb that cycles usa sells and custom make your own axle. See what cycles usa sells, they may have a wider bb as well.

[lostrack]

I've ordered a 148mm bb which is designed for the frame - it will give me 5mm more space. Also some cranks that have a 34mm offset. So instead of 170 clearance I should have 182...ish!

Matt - are you good to pop down some point this weekend (Sunday maybe?) to help me fit this new BB? Do you have the tools for an ISIS fit?

T

Also ordered some freewheel cranks and a white industries front freewheel for a little experiment I want to try...

[Idontwanttopedal]

Yeah I been down got tool in car so I don't forget it. Might come down on the bike

[lostrack]

A productive weekend - got the batteries tidied up, sorted out some cabling (thanks Idontwanttopedal) and got the beast stirred up for a summer of riding!

Now the evenings are longer I can take it out after work -

BobC's new 68T and keeper plate is working wonders, the chain didn't come off at all during the whole session, the first time that's ever happened!

I only had enough time to half charge the pack to 45V but the extra speed is great - I'd say about 36-37mph, so you don't have to be WOT all the time. That being said, the real fun is going to be in the woods, not on the open road.

Lots of stops and starts generally - trying to get the bike to wheelie, I seem to be quite gentle on it. The motor got to 100F and the controller was cool. Cycle Analyst said I was drawing max 5KW power, so there's still alot of room to play with there - I could hear Matt's slipper clutch kicking in, so I can tighten that up for more acceleration / power draw / wheelies

Ordering some parts soon - rear spring can't handle the weight!

I'll be making some more videos soon...stay tuned

[recumpence]

Give the clutch nut 1/16th of a turn and hold on! Wait till you feel that thing pull at 9kw. You will be wheelying whenever you feel like it.

Matt

[bobc]

Excellent - glad it's working! Great cycling weather in the northwest UK today: did you put anything on utube?

[lostrack]

let me have a look on the go pro

[knoxie]

Looking forward to seeing some more videos as you have already proven you can ride!! yes the weather at the moment is a bonus

[lostrack]

On the side, I think the weight at the moment is 32-35kg. I have this luggage weight thing which only just picks it up. You have to hook it on the frame - almost exactly at the mid-point where the motor is. So, I've got good weight distribution too.

Ordered a bigger 450lb shock today so it won't bottom out when fatties ride it! (no names... )

[lostrack]

Hi everyone,

Some wierd shit is going on with my packs. I have plugged each pack individually into the balancer just to check why I was getting inaccurate cell counts

2 of the 5s packs are showing 4 cells only
The 6s pack is showing no cells - even though we soldered the black balance lead on correctly this weekend.

When I plug all the cells in through methods boards, it shows 11 cells total. It should be 12s3p, all packs 5s and one 3s2p.

What should I do?


I don't want to balance the packs as the ones it can't see will be left higher and may be overcharged(!)

Thanks again

Tom

[knoxie]

Are you using balance wire extensions from the packs or are you plugging straight in to the balancer? what are you checking them with? sounds a bit strange

[Idontwanttopedal]

Had go on this bike need spend some money now thanks Tom. My bike just feels so slow and weak.

If you need hand on any thing let me know I really think you need to rewire your hole pack

[lostrack]

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Whoops...

Beef =

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A few more pictures and a new video on page 1.

Enjoy:)

Definitely glad I went to the trouble of full sus on this build. Riding across a field at 30mph, even grass turf is enough to almost shake you off the bike, and this is with some of the best DH suspension available.

No chain skip issues (yes!) and it's the first time EVER I've not done the walk of shame to get home:)

I was very cautious of other people on the field and in the singletrack. Hope you can tell from my riding.

To do:
considering running gears, not so sure it needs it anymore.
Throttle is the weak point. So twitchy. Going to run a cycle analyst current throttle, see if that helps.
Wire up Methods LVC boards to throttle.

Temp gauges on controller & motor. Can't get the controller to heat up at all, and this is with constant abuse.
Motor gets to "temp gauge 40'C" but feels much more like 60-70C to my hands. Must attach it properly.

Any tips on getting a probe inside an Astro?

[knoxie]

Super nice job on the bike video is rocking too, damn that thing is fast, looking forward to some more video at higher resolution maybe? you got all weekend although the weather aint looking that special is it

[recumpence]

Tom,

I got your PM.

It is easy to mount a temp probe inside the motor. Merely remove the rear cover and glue it to the windings.

170 degrees F is the safe limit for these motors.

Matt