E-kross astro 3215 build

Rouckie · May 13, 2020

I finally got to make my next bike. I was planning on making a bike from scratch, complete frame and swingarm, but decided against (work, kids, ...).

The donor bike is a kross moon, size L:

The motor I will use is a astroflight 3215.

It will be a left side drive, single speed, dual stage.

As controller I will start with a VESC 6 and might upgrade to a controller a friend of mine is developing. This way I can increase the voltage of the battery pack beyond 12s.

The battery will be in a backpack while testing how much power and capacity I need. Later I might add a battery on/in the frame.

Let the build begin:

Rouckie · May 14, 2020

Making the part that will reconnect the frame:

stock material:

Some chips later:

After operation 2:

A "little bit" later:

Merlin · May 14, 2020

Holy cow... That looks promising :shock:

bionicon · May 14, 2020

nice metalwork

DanGT86 · May 15, 2020

Spectacular! Looking forward to this one. How aligned did the frame stay when you cut it? Did you take before and after measurements? I've always wondered what kind of stress frames are under from the original manufacture. Id expect it to pop out of shape when cut.

Thats a nice looking part. How did you fixture it for machining? How many setups to get to that point?

Its funny that this is your plan to not spend too much time on it. Makes me wonder what your complete frame was going to look like. :lol:

Rouckie · May 15, 2020

@ DanGT86:

Distance from bottom bracket to top of seat tube was shortened by 4 mm when I cut the frame.

6 setups

Maybe in the future ... :wink:

Rouckie · May 17, 2020

Ready to rebuild the front triangle:

Checking clearances and functionality after spotwelding:

DanGT86 · May 17, 2020

Are you going to heat treat the frame when you are done welding?

Looks like a good fit. Always nice when things work.

Rouckie · May 17, 2020

No heat treatment planned. Material is pretty thick or in not highly stressed region...

Rouckie · May 22, 2020

Next up, machining the swingarm:

alignment:

freshly cut:

E-kross astro 3215 build

Rouckie

100 W

Rouckie

100 W

Merlin

1 MW

bionicon

1 kW

DanGT86

100 kW

Rouckie

100 W

Rouckie

100 W

DanGT86

100 kW

Rouckie

100 W

Rouckie

100 W

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