I finally did some work on the Motoped this weekend.
The drive system is mechanically complete. I am letting the cat out of the bag, so to speak, with this post. What I mean by that is, my extremely high power systems are moving from 1/2 inch shafts to the 7/8 inch shaft as shown in these pictures. (I will start a new thread on that at some point in the near future). Basically, the same bearing tube my drives have always used is maintained. The largest ID bearing I could fit into that existing bearing tube was a 7/8 inch needle bearing. So, my twin motor drives, and single motor drives that pull more than 10,000 watts will come with this new shaft. The large pulley hub is, now, stainless rather than the original aluminum and is TIG welded to the shaft. This eliminates one potential failure point (hub mounting to the shaft) and is EXTREMELY strong. The freewheel adapter is stainless also. It is made in a way that is reverse-able. So, switching from right hand drive to left hand drive is as simple as removing the freewheel and the adapter as a unit and flipping it around on the shaft and reinstalling it. Super simple.
This is my first drive to use a prototype 112 tooth main pulley (coupled with 16 tooth motor pulleys). I had a few of these huge pulleys made for situations like this where additional reduction is needed without adding another reduction stage. The pulley is quite large. So, adequate room within the chassis is needed. Therefore, this is not applicable to every installation. But, for the bike with room (and requiring additional reduction for super high RPM motors), this large pulley is a great option.
I fabricated a torque arm running from the stock chain idler bracket location to the output shaft. This will eliminate any chassis flex that would otherwise be encountered from the crazy high torque of the chain at that point. I simply TIG welded a split collar to the end of a 1/4 inch thick aluminum plate and machined the idler slot into it, then buffed off the welds for a clean look. The torque arm clamps around a bearing at the shaft end. One thing that is missing is a split collar that will go on the end of the shaft to prevent the torque arm from drifting outward on the shaft. I have that collar on order.
I also installed my new high capacity cooling fans onto the end of the motors. These new fans draw only 60 watts at full throttle, yet pull far more cooling air through the motors than my first generation fans.
If my math is correct, the overall gearing should be at or a bit below 40mph at full throttle at 12,000 motor RPM. This should be WAY beyond super cross HP per pound.
Oh, lastly, it looks like my initial estimate of 72ah of lipo in my pack was too high. My main box will hold 12s-64ah. However, I plan to TIG weld an aluminum box shaped roughly like a gas tank to hold various electronics and I will [hopefully] do my best to cram as much additional lipo into that enclosure.
My guess would be about 6 weeks to get it running. We will have to see if that estimate is anywhere near reality. :wink:
Matt
