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  1. solar.g

    Mid Drive with Internally Geared Hubs

    On my mid-drive, I use CA to limit current to 10A @24V so less torque load on rear chain from Cyclone motor. I use Wippermann Connex 808, which gives me ~4000km life on rear chain, 8000km on front (highest load on rear, motor + pedalling, front chain only gets pedalling load). Measure stretch...
  2. solar.g

    JP spot welder

    My pre-built unit just arrived. Thanks, Riba... Be a little while before I get a chance to use it; will post photos when I can.
  3. solar.g

    Let's hear it from the Mid-Drive Kit Owners !

    Forgot to mention before, when we replace the Cyclone gearbox grease we don't put more than a teaspoon or so of 50/50 gear oil/molly grease in to replace it. This means that there's no need to replace the seal between the motor and the gearbox, as the oil/grease slurry isn't likely to get up to...
  4. solar.g

    Let's hear it from the Mid-Drive Kit Owners !

    The OP wanted to know what people had. So here is a summary of ours, from Melbourne, Australia: I and more than 8 of my friends have Cyclone-based mid-drives, on recumbent trikes or recumbent bikes. We all have different requirements, but requirements we all share include the ability to climb...
  5. solar.g

    Mid Drive with Internally Geared Hubs

    FWIW, my friends with NuVinci IGHs do like the ability to continuously adjust the "gear" to motor output (speed vs watts) & cadence so that pedalling is comfortable & power consumption is low. We do a lot of weekend rides on old "rail trails" (decommissioned train lines, turned into bike paths)...
  6. solar.g

    Mid Drive with Internally Geared Hubs

    Have personal experience with 8 IGH installations on recumbent trikes, amongst our ride group: 1. I've got >4000km with Cyclone 480W/Lyen on Trisled recumbent trike with 20" wheels & Rohloff, over 9 month period. 2. Wife has >3000km on identical installation, over 6 months. Recently had chains...
  7. solar.g

    Cyclone motor noise reduction in trike mid-drive builds

    Thx for the tips. I've tried all the usual things - gear oil/grease slurry (helps a bit), checking mounting for resonances (not yet finished investigating). My 2 trikes run Lyen 3077 9-FET controllers, so don't know if the controllers have different noise signature to Kelly or internal...
  8. solar.g

    Cyclone motor noise reduction in trike mid-drive builds

    Just a few thoughts about Cyclone motors, controllers, gearboxes and noise: I'm part of a group of riders who, between them, have a dozen or so Cyclones in bikes/trikes. They each have their own "sound signature", which we are at a loss to quantify to a particular cause/source. My question is...
  9. solar.g

    cyclone with nylon gears

    In car gearboxes straight cut gears are noisier than helical cut ones. If you can make nylon gears, can you make helical gears, metal ones? You'd have to make a new motor-shaft gear too, though.
  10. solar.g

    * * * The 1000 Mile Club * * *

    After 6 years & 20,000km without electric-assist: From 21st August 2013 to Christmas Day, 1000 miles (1610km) on Trisled trike with 480W Cyclone, Lyen 3077 9FET controller, Ping 20Ah 24V battery, CA limited to 10A continuous. Now 2000km. CA limited to 10A continuous (up to 20A peak @24V). Top...
  11. solar.g

    Cylindrical cell fusing and fuse calculation

    You stated earlier: "Lets assume that we use nickel sheet which is .20mm thick and we need 50A discharge on the pack." Are you proposing that you cut nickel sheet of that thickness to a particular width to be a fuse for each cell? A fuse is actually a complex device, working on instantaneous and...
  12. solar.g

    Is Cyclone output shaft easy to remove?

    Many thanks to "mrbill", "boostjuice", & "dlogic" for taking the time to reply. Winner's award goes to "dlogic", who shared the secret information with me: "yes, i did take my gearbox apart. Underneath the rubber seal you will find another cir clip that has to be removed. Leaving it in place...
  13. solar.g

    Is Cyclone output shaft easy to remove?

    I was hoping a bit of heating/cooling differential (heatgun on housing, freeze-spray on shaft) might help, but before experimenting I really want to get my hands on an old sacrificial Cyclone gearbox. I'm not killing my working motors just to see if it works! Anyone got an old Cyclone or just...
  14. solar.g

    Is Cyclone output shaft easy to remove?

    I've got two recumbent trikes with Cyclones that have double-freewheel adapter of my own design (to use White Industries ENO freewheel & Surly sprocket). I also use a pair of 6000RS bearings to support the outer end of the drive shaft. But I'm currently using a sleeved M8 bolt screwed into the...
  15. solar.g

    Rohloff SPEEDHUB 500/14 (for mid drive)

    Correct on "assist" - hills and headwinds and getting home in a hurry in foul weather. Today I threw my front chain and lost one of my Wipperman Links (crank boom was not tight as it should be, so chain was too sloppy). Didn't have a spare linik with me and the bike shop I stopped right outside...
  16. solar.g

    Rohloff SPEEDHUB 500/14 (for mid drive)

    My wife & I have recumbent trikes with Rohloffs for the last 5 1/2 years. Done over 20000km, non-electric. Last 3 months, I've put Cyclone 580W/24V on, done 1400km so far. Wife has done 500km on hers, done 6 weeks ago. We drive them a bit like manual car. In lower gears, can apply (moderate)...
  17. solar.g

    Source for 1.375 x 24tpi EXTERNALLY threaded tube/pipe?

    According to Sheldon Brown's website (http://sheldonbrown.com/freewheels.html), and others, there are subtle differences between 1.375", 1.37", English/French/Italian 24TPI threads. Angle of cut and a few thou difference can make one easier or harder to screw on (or impossible to screw off). I...
  18. solar.g

    2.7volt 3000 farads, pretty cool

    As this article says: http://news.nationalgeographic.com.au/news/energy/2013/08/130821-supercapacitors/ "The energy density of supercapacitors pales against lithium ion batteries, the technology typically used today in phones and laptops. Lithium ion batteries store perhaps 20 times the energy...
  19. solar.g

    How to build a individual 18650 battery pack, Example 12S8P

    Danger with soldering, as stated elsewhere by more experience ones than I, is that heat from soldering iron soaks into the cell and overheats the electrolyte (and other chemistry) just under the end you're soldering. Very difficult to manage/limit the heat-soak from the soldering iron through...
  20. solar.g

    cheap cyclone motor?

    AFT make money not on the parts or the invention but on the labour they charge. So they probably won't do mail-order on parts kits. They don't, from what I've been told, even like telling their (paying) customers any specifics on any of the parts they use. Its all about charging for the labour...
  21. solar.g

    cheap cyclone motor?

    Planetary gears being available as a spare part are a sure indication that Paco expects those parts to be a consumable. 12000km on a 1200W motor is not bad. Do you have a Cycle Analyst or other means of monitoring/recording your typical amps/watts? Would be nice to know what sort of power you've...
  22. solar.g

    cheap cyclone motor?

    Of the Cyclone owners in our group, only one has done the official AFT oil conversion. 2 of us have done our own cheap-assed oil/moly grease slurry conversion. Only got 1000km on mine, and haven't pulled it apart to see how it compares with others' standard gearboxes. There are a couple of...
  23. solar.g

    Considering GNG & Cyclone mid-kits, what are the consensus?

    turbo1889, Rohloff is expensive because it's very well engineered. They specify it can cope with tandem (ie: 2 people) installation, if geared properly (the manual goes into lots of detail on how to get it right and wrong). I limit my current to 7A@24V in CA (170W), and due to limitations of...
  24. solar.g

    Considering GNG & Cyclone mid-kits, what are the consensus?

    Yes, one of our friends with 1200W/36V Cyclone/Kelly on Trisled trike has had AFT upgrade for oil-lubricated gearbox (with external oil reservoir). Didn't get ceramic bearing upgrade, though. She does lots of km, often towing trailer. I, and another in our group, have taken our gearboxes apart...
  25. solar.g

    cheap cyclone motor?

    That sickbikes link seems to be dead now. But +1 on strength of Cyclone gearboxes. Ride with someone who has 1200W/36V Cyclone with Kelly, towing trailer behind trike. Does lots of km a day, no problems. Of the riders in our group, at least 9 have Cyclones of all sizes from 200W-1200W and no-one...
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