Hey Guys!
Glad to be a part of this forum. OK, lots of questions. I will try to answer them as I can.
The motor and drive system sounds unique. the motor itself is basically silent other than the windings pulsing. The belts have a sort of quiet, muffled supercharger whine. Interesting, but not obtrusive. I have not run the bike yet. But, my CNC runs the same style motor (though smaller) with a belt drive. So I have an idea how it will sound.
These motors are super efficient. Therefore they run cool and with a HUGE amount of power per pound of weight. I have a different motor in an RC car that is 1/4 the weigh of this motor and 90% as much power. That motor (a Neu1515) is up to 97% efficient. So, I am hopeful it will be fine. If heat ever becomes an issue, AXI makes a fan that mounts to the rear of the motor and spins with the can.
I was concerned about the torque on the spokes also. I actually have an extra $500 sitting here to buy a CF Spin or Aerospoke wheel with disc brake flange for the left sprocket if I wreck this wheel. That being said, I just had to see if this wheel will hold up. My thought was this, I have a mountain bike with a 24 spoke 26 inch wheel and disc brakes. I crank on the front brake and do endoes all the time and have never had a spoke problem. So, I do not see this wheel getting more torque put to the spokes than that wheel. Of course, my logic may be fatally flawed. That is why I am holding some cash for a decent wheel if need be. :wink:
I went with a BMX chain because it was conveient. Also, you can buy super heavy duty chains that were designed for sprocket grinding on freestyle bikes. I will go that route if I need to. Also, my sprocket is 7075 aluminum it was a nightmare to machine! It should hold up. If not, hello steel sprocket!
The ESC (speed control) will have no problem at all. I have 3 of those same controllers. They run nice and cool up to 127 amps at 48 volts in one application I have. I have never had a problem with one no matter how hard I push it. I can program a soft start/throttle ramp as well (it is USB programmable). I will probably program in a delay to ease the driveline load. Also, there are a couple guys in the UK that are running similar setups (though much smaller) with great success. I just found this out a couple days ago. Funny how you think you are the first to try something.............
The cells are 10C cells. I cycled them and confirmed this. the pack will weigh 80 ounces with wiring and casing. This may seem impossibly light from E-bike standards. But, actually from an RC standpoint, there are cells that are lighter with better ratings, but they are HUGELY costly!
I appreciate the kudos on the project and the machining. I am self taught and have very basic machines (and small). I sold a spare car we had to buy it all and taught myself everything. I even program in G-code!
Please forgive my general ignorance in E-bike technology. I am knowledgeable in bike building (I had one hand made bike featured in BMX Plus when I was 20) and RC. but, not in E-bike per-se. But, I was surprised how expensive everything was. Not that it costs a fortune to setup an E-bike. But, it is alot of money for the ratings of what you can get in typical E-bike equipment. I am not trying to insult E-bikes (hub motors, etc). I am just frustrated that there is so little in the way of true technology applied to this hobby/sport by the majority of manufacturers. I had one e-recumbent designer contact me Wednesday. He is sending up a rep to see my bike (for ideas?). Weird. I haven't even run it yet. But, that tells me there is a pent up desire for better e-bike technology. Is this the future of e-bikes? I doubt it. But, it may be a step in the right direction. I just need to get it running and see!
Who knows, it may be a flop. But, I have done alot of research on this. I may have ratios a bit off or some other bugs here or there. But, the bike should perform quite well.
Then again, this may prove to be a huge waste of time!
Matt