rodgah
10 kW
that is nuts cant wait to see it done!
it's all your fault. your bike was my inspirationrodgah said:that is nuts cant wait to see it done!
Yes exactly. The frame is just clamped to the jig made of steel (which we have plenty of, and is easier to weld). I will NOT try to weld those two materials togetherwaynebergman said:crossbreak I think the steel is just in the jig to keep things in line for repositioning the aluminum fabrication.
NOW you can start crying:madin88 said:if i look at the pic with the saw cutting the frame i could just cry, but i think the finished bike will be more stable than before
Will the batterie box be removeable or fix?
izeman said:no. the battery box will be fully welded to the frame. actually it will replace big parts of the frame. the main problem is to find a way to position everything in a kind that it's easily serviceable, durable, and idiot proof. i think i will be able to acchieve all three goals.
izeman said:NOW you can start crying:
to be honest: i don't really like it. too organic. i like straight tubes and frames more. but the whole bike was a steal, so i bought it. and i may NOT have cut a large frame. but they had small ones left only.rodgah said:that is my favorite frame, even though konas are not very exotic I just really like its shape.
i've seen them. but they are way too big. the board with xt60 male and female and 10awg wire to the battery can hardly fit insight the 50mm height of the battery. so those plugs where the only ones possible.crossbreak said:i like the board as well. Even HXT plug are available for through-hole soldering, so you dont need to use XT60. They are called "HXT Pre-installed Bullets"
i will make the welding preparation only - cutting sheet in pieces, cleaning and dot welding. the final welding and welding to the frame will be done by a professionell welder - i don't trust my welding if my life depends on it.crossbreak said:Great to hear that you go for alloy welding in the end, really keen to see your results!
thanksmadin88 said:izeman said:no. the battery box will be fully welded to the frame. actually it will replace big parts of the frame. the main problem is to find a way to position everything in a kind that it's easily serviceable, durable, and idiot proof. i think i will be able to acchieve all three goals.
it looked like the battery will be in a separate box like a "box in box". is it not?
make it removeable would be great in winter. i think of leave the bike outside and store the batt in the warm house, or take it for charging.
idiot proof is always good If i build something, i personally always think what will happen if it gets in the hands of people who have absolutely no knowledge about this stuff.
the connection board for the batteries is very nice. no inconvenient balance wire soldering etc. just put the LiPo in there and connect it. Nice!
I think it would be easier to use rectangular aluminum tubing, and cutting an access panel, instead of building the box from scratch. If you can't find tubing that's large enough on both sides you could cut the aluminum tube in half horizontally and weld in a panel on one side and an access panel on the other side (which I think would still be easier than building a complete box).izeman said:today i took some 3mm thick card board (for architects) and started to cut out the parts for the box.
IMO an oval tube, with curves near the BB and top-tube would be better aesthetically. You might not be able to find oval aluminum tubing that is large enough but you could use a piece of round aluminum tubing or pipe and cut it in half horizontally and weld in a panel on one side and an access panel on the other side. If you want curve(s) you could bend the aluminum pipe before cutting it in half.izeman said:using CAD i constructed the battery box's shape.
Is it worth contacting either of these companies and asking if they will sell you a small amount (for a prototype )?:izeman said:We have some AL7020 to make the box out of, so a good match to the AL7005 the frame is made of.
but it was very hard to find aluminum tubing of that dimensions, and impossible some 7xxx alloy. at least not the amount you need to build one bike. small amounts are very hard to find.
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Round tubing might be a relatively easy material to source. If so you could make oval tubing something like this (cut a piece of round tubing in half and weld on sides):izeman said:thanks mitch for sharing your thoughts. i wanted to build this with tubes when i started.
so i had to go for sheets. it's some work to cut and weld, and it may not look as good a a tube, but i have no other way of doing it.
oval tubes for connecting to box to the frame surely look nice. i will think of a way to make them. we'll see
if i move it closer to the bb then the chain will hit the rear frame pivot
Next time try this glue, works great with a wide range of material and it definitely won't eat a grip:
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Auro 390 Contact Glue 75ml
Price per Unit (piece): £4.99
Solvent-free and thus recommended for handicraft work with children. Bonds broken objects that need durable mending: paper, cardboard, wood, many plastics, metal, glass, ceramics, etc. The glue residue is bio-degradable.