Giant DH Comp Drop Out adapters and conversion

[GCinDC]

dang man, that's a ton of work for these custom jobbies. i totally appreciate that you're doing it!

i'm in for one, and if anyone stateside wants one, let us know - might be cheaper shipping the last leg from me than NZ.

[dbaker]

ES power junkies will really appreciate clamping drop outs; especially those using regen

[waynebergman]

Nice going KIWI. Keep her going! .....................wayne

[Kiwi]

Well progress has dropped back a bit with a few challenges and christmas and family taking time priority.
I have the wheel fitted now, I found once I installed the disk I had a bit of a space issue.
I went to build up the HS and found my spokes were not suitable, so I laced up a new model NC motor.

For those of you who dont know, the next versions of the rear nine continent motors will have the cable exiting the side of the axle, not the end. So like the HS motor. Only NC have done a better job.

How ever, I found that once I spaced the disk out to fit a normal disc brake caliper, there was only just enough room for the cable.
The heads of the screws that hold the disk on just brush the cable outer.

I can compensate for this in the design.

It was a good idea to mod the 150mm adapters, it has taught me a lot.
Also I have had the request to make them clamping. THis I can do.

Dont hold your breath for getting them before xmas. But they are going to be very cool.

[neptronix]

WOW. I don't own one of these bikes... and never will.. but as a passer by, i'd like to say, what a work of art, dude!! keep this good stuff coming

[dbaker]

Very nice work, Kiwi

[waynebergman]

Looking good Kiwi. I am running an 11-32 tooth on my HS 3540. Do you figure the 11 tooth I am hoping to run will let the chain clear its chain stay with the new design you are working on?

For me I would be fine with opening up my drop out holes to slots in my frame I think, if your bolt on versions would require that, should you need to change its design for chain rub issues. I am not sure what you have planned but I am guessing it may make things easier on your side to keep the original brake mounts and axle height within the frame as originally located if you choose this as a design compromise. Even if your units mounted outbound of the bikes original drop outs and the non drive side units fastened themselves to the frame with longer machine screws to the frames original brake mounts which would mean the original brake mounts could still be used for brake mounts as well as holding the new drop outs for the non drive side. Just a thought if the unforseen causes you grief with spacing issues.

I am sure many like the idea of not cutting into the frame in any way but for me I am over that part of it. As long as the units look good and bolt on with out alignment issues etc I would be very satisfied with this kind of work around for making the frame hub ready. Say once the new units were bolted on you would have a nice line to follow for cutting the 10mm slot in the old drop outs and file to finish. Could be very easy for owners to instal still, even though a bit of cutting and filing if this compromise would work for you on your end.

I am sure you will come up with a clever work around for the issues at hand, just thought I would send along this idea for you should you be looking for any input or feelings from potential end users. Good luck with the process and keep us in the loop.

Wayne

[Kiwi]

while I have not proven it, I am quite sure that the chain will touch when on the 11 tooth. Only ways around this is to run a bigger front sproket to lift the chain clear of the stay, or run a 5 speed 11-32 if there is such a thing. This would bring the chain in.
I have sold out of my 11-32 clusters, so currently cant prove it.
I have spent way to much time on this to go changing it now. If I was charging my normal design rates these would be worth thousands of dollars each, but as this is also my hobby and I love es, and am trying to establish an ebike component design business, I am basically selling at manufacture cost to ES members just to get some of my work out there. I have a few improvements to make, but these will remain a no cut solution for the Giant DH comp.

[waynebergman]

Sounds good Kiwi. Awesome! In my case I am cool with just not using the 7th gear. I believe my 6th gear on my 11-32 is a 13 tooth and that would be just fine by me for my tallest gearing. So for me, don't worry about chain rub on the 11 tooth sprocket..............wayne

[Kiwi]

Hi everyone.

Firstly, a sort of apology for the parts taking a while. I know you are all keen as beans to get riding.
With out elaborating on circumstance, I had my life rocked in a rough way over xmas, one of those WTF moments that seem to keep getting worse. Things have calmed down now, but I am still on alert, but back into bikes. My only advice, if there is sh*t gong down with the people you love, get it out on the table early, don't pretend its not happening or it will blow up in your face and be a hell of a mess to clean up.

So, the 135 clamp adapters are designed and will go to get cut tomorrow.

You all asked for the clamp, but i have my doubts if you will be able to make the drop outs flex with the bolt, as they are 14mm thick. Still it will give you the security your wheels not going to fall out.

Also, they are really 138mm adapters, you will flex the frame 3mm, which it does easily, it was the only way to get the disk caliper to fit.

Here they are.
Drive side



Disk side

[GCinDC]

sorry to hear about the family stuff, kiwi. good luck getting thru it.

i'm psyched for the torque arm. looks awesome. i especially appreciate your effort to make it clamping!

dhcompadaptercomparison.jpg (25.96 KiB) Viewed 683 times

that bolt will totally allay fears about the wheel coming out! as far as clamping tho, i get your point. i wonder if the bottom sides would rather split than clamp if really torque'd on.. are those empty holes in the side to allow some flex?

i'm ready to paypal you whenever. i think i'll just get one, but am willing to get more for anyone stateside who wants one. should be $5-$10 priority mail from my house. not sure how it works out from NZ to me..

hey, one more Q: that axle clamp on the normal DH Comp, will i be able to tighten that down, or will it have to stay loose cause the adapter's in the way?

great job, happy cutting! can't wait!

[waynebergman]

Sorry to hear things have been on the bumpy side for you as of late. Hope things smooth out for your new year. Thanks for the update Kiwi, and I want to let you know I am still on board for a set when you get them up and going. I am in Canada so I can PM you closer to the time regarding shipping etc. Good luck with the project and thanks for seeing it through. ......................wayne

[binlagin]

Those look absolutely awesome, I can't wait to get mine!

Crusoe has been in contact with you for my set... so don't worry that I'm not on your list. Just make sure he's marked down for two!

Keep up the good work and GL with the real life issues.

[crusoe]

Awesome work Kiwi! Can't wait to get them on the bike. Hope things pan out for you on the family front

Where abouts are you located in Canada Wayne? Binlagin and I are in Ottawa - we should get a DH comp riders day setup if you're close! I have 150 acres of land with some nice doldrums and trails throughout that these bikes would love to rip!

[waynebergman]

Hey Crusoe I will PM you regarding the ride. I am in British Columbia so if I ride my bike there with battery charge times etc it may take several months to get there. Can I stay for a while? hehe
On a more serious note maybe we can work out a piggy back shipment when the time comes for both sets to come from NZ to Canada and then split the order up to ship with in Canada after it arrives. I have no clue on shipping from New Zealand to Canada maybe it is not worth worrying about. Good luck with your bike. ...........wayne

[Kiwi]

Shipping is weight based, there would be little savings to be had sending together, in fact it might cost more if you have to re ship it once you get it. Shipping is less that $20US per set.

[waynebergman]

Awesome Kiwi, shipping rates sound good.

[binlagin]

Hey Kiwi!

How did the cutting go from earlier this week? Did it turn out how you planned?

[Kiwi]

IN regards to the Cromotor.

There is 15mm of room for an axel. To make 16mm fit you can either not have the clamping bolt, make the clamping bolt m5, or file a mm away so the clamping bolt can drop down. So yes, with a mm of tweaking, it should work.

In retrospect, obviously I should have made the clamping bolt low enough to accommodate the 16mm axle.
Version 3.0 for that one.

We have had a bit of a NZ holiday here, so lazer is shut down today. Will get parts tomorrow. Will post a picture.

[crusoe]

Pumped to see the pics

[Kiwi]

I rejected the parts today. They have to cut them again. Not good enough for my standards or ES members.
Will pickup again tomorrow.

[GCinDC]

I rejected the parts today.

I appreciate the QC, Kiwi. PM me your paypal anytime... I'm so psyched to get these!

[crusoe]

Any more updates on the dropouts?

[binlagin]

We are ravenous arn't we? Sorry Kiwi! We are just super excited LOL

[Kiwi]

GRrrrrrr!

Picked up the parts, still crap. The lazer apparently needs a service, currently blowing allot of slag off the back edge and making a general mess. To top it of, the machine operator thought he would be nice and grind all the slag off, but rounded off all the edges, so there will be gaps everywhere.
I'm going to pick out the better bits and make up a couple to try them, I will make them available at a discount if they function properly, which they should.
I not planning on paying for these, they can do them again after the lazer is serviced.
The shite part is that I end up spending ages cleaning off the slag to get the parts to fit together, hardly worth my time.

But I will get some together this week, and some more with fresh parts in a few days.