Oatnet's x5403/Norco A-line, and Front-Mount battery stuff

Show off your E-bike creation here.
User avatar
sn0wchyld   1 MW

1 MW
Posts: 1754
Joined: Mar 18 2011 8:27pm
Location: South Aus.

Re: ??????? vs x5403 - Fight!

Post by sn0wchyld » Apr 05 2012 7:04pm

MattyCiii wrote:Oatnet, your A-Line and Adams both set an extremely high standard for meticulous planning, quality craftsmanship, and flawless execution. Each a work of art!
:cry: :cry: :cry: :cry: :cry: :cry: :cry: :cry:

your right though, these do show my work up to a pretty massive degree. I just tried to build a 8ah pack for the front, but sadly im about 5mm short of fitting it all in, and ive gone and bought another case big enough for 10ah + a charger but its too damn deep! :cry: :cry: :cry:

It looks like the shock under full compression may hit the bottom of the case? or is it propped out enough that the support bar will go behind the case?
looks great though. very subtle for so much power!

MattyCiii   100 kW

100 kW
Posts: 1367
Joined: May 05 2007 2:06pm
Location: Boston, MA, USA

Re: ??????? vs x5403 - Fight!

Post by MattyCiii » Apr 05 2012 8:29pm

Well of course I meant no disrespect to the rest of us us A-Liners (and Andje the E-Liner)!

These builds just set the bar very high, and are an inspiration to strive for the best.

Meanwhile my A-Line frame cowers behind the living room couch in shame, not even rigged up to work as a kick-bike :cry:
Image

Shameful!
1st build: Dahon Jetstream folding bike. Quick, reliable, capable of 32mph. Light enough to lift, folds for easy transport by car/bus/train.
2nd build: RC powered 2009 Norco A-Line. Top speed 39mph. Built like a tank, it's resistant to Boston potholes, can stop on a dime, easily goes up/down curbs when necessary.
3rd build (just started): Scratch build ultimate utility bike. Based on a common power module using a NuVinci left side freewheel.

User avatar
oatnet   10 MW

10 MW
Posts: 2341
Joined: Apr 26 2007 3:03pm
Location: SoCal, USA

Re: ??????? vs x5403 - Fight!

Post by oatnet » Apr 05 2012 9:17pm

Thanks Teklektik! Having everything oversized helps, from a distance. Up close, a lot of people do double-takes at the size, especially children.

Thanks Kepler! You are right, it took a lot of work to make this bike look uncomplicated, I know from your stealth builds you appreciate that.

Thanks MattyCiii! I really like where Adam is going with his build.

Thanks Ypedal! I remembered you asking me about that luminator I bought a LONG time ago, and wondered if you would remember it... Yep, it TOTALLY rocks. I planned to put a matching one on the right side - now I am not sure I need one. Hmm, when I go to 144v, I could probably put two in series...

sn0wy, I disagree, your build rocks and you have been riding it while I have been being a heatshrink Nazi. With so many builds it is hard to not get lost in the mix - I'll bet 98% of the people here don't remember 10% of my builds. The builds that get remembered are from people who post 20 times a day.

Anyhow, full compression on the front shock is indeed close to the case, but based on my measurements it should just barely clear, sliding behind the case a little... This is a street ride only - well I may ride on the surf some - so I should only see full 200mm compression on a pothole big enough to give me other problems.

Anyhow, onto some build photos. You may remember the packs I terminated in my a123 prisimatic pack building thread:

http://www.endless-sphere.com/forums/vi ... 15#p555239

[attachment=17]a_IMG_2323.JPG[/attachment]

[attachment=16]b_IMG_2325.JPG[/attachment]

[attachment=15]c_IMG_2326.JPG[/attachment]

[attachment=14]d_IMG_2331.JPG[/attachment]

[attachment=13]e_IMG_2343.JPG[/attachment]

[attachment=12]f_IMG_2344.JPG[/attachment]

[attachment=11]g_IMG_2345.JPG[/attachment]

[attachment=10]h_IMG_2346.JPG[/attachment]

[attachment=9]i_IMG_2347.JPG[/attachment]

[attachment=8]j_IMG_2351.JPG[/attachment]

[attachment=7]k_IMG_2316.JPG[/attachment]

[attachment=6]l_IMG_2319.JPG[/attachment]

[attachment=5]m_IMG_2353.JPG[/attachment]

[attachment=4]n_IMG_2355.JPG[/attachment]

[attachment=3]o_IMG_2356.JPG[/attachment]

[attachment=2]p_IMG_2357.JPG[/attachment]

[attachment=1]q_IMG_2361.JPG[/attachment]

[attachment=0]r_IMG_2365.JPG[/attachment]
Attachments
a_IMG_2323.JPG
First I put on (4) 45a andersons, crimp first, then solder. These are (4) 14ga wires, equivalent to 8ga.
a_IMG_2323.JPG (55.79 KiB) Viewed 3887 times
b_IMG_2325.JPG
Join the 4 into a block. I later added a zip-tie and heat shrink to the quad connector.
b_IMG_2325.JPG (71.58 KiB) Viewed 3887 times
c_IMG_2326.JPG
Bend the power leads back
c_IMG_2326.JPG (83.24 KiB) Viewed 3887 times
d_IMG_2331.JPG
Three blocks of (8) cells for a 24s pack.
d_IMG_2331.JPG (103.65 KiB) Viewed 3887 times
e_IMG_2343.JPG
Every pack needs a fuse. Here I am paralleling two 90a breakers, for 180a rated throughput. They won't actually trip until far higher than that, but I have popped breaker pairs like these in a dead short, and that is what is important.
e_IMG_2343.JPG (57.79 KiB) Viewed 3887 times
f_IMG_2344.JPG
Connectors are wired up and ready to be installed
f_IMG_2344.JPG (87.55 KiB) Viewed 3887 times
g_IMG_2345.JPG
All bolted together with a little locktite
g_IMG_2345.JPG (69.07 KiB) Viewed 3887 times
h_IMG_2346.JPG
Installed in the middle of the pack
h_IMG_2346.JPG (114.97 KiB) Viewed 3887 times
i_IMG_2347.JPG
I slip the circuit breakers into sleeves of unshrunk heat shrink sleeves to insulate them from the rest of the pack and make sure nothing is obstructing the button.
i_IMG_2347.JPG (65.09 KiB) Viewed 3887 times
j_IMG_2351.JPG
Here you have a complete wired 24s16ah a123 pack with circuit breaker weighing 23.2lbs.
j_IMG_2351.JPG (71.47 KiB) Viewed 3887 times
k_IMG_2316.JPG
on the bottom front of the pelican are the main power leads. I drilled holes through the bottom of the case, into square hollow supports on the underside. I cut holes on the inside of the supports and mounted power switches inside them. These wires lead to those power switches. The other side of those switches is connect to the 4ga wire straight back to the controller.

However, I needed clearance for the power wires, so I made this little platform for the 3rd sub-pack to sit on, with channels cut out for the power wires. Crude, but functional.
k_IMG_2316.JPG (57.58 KiB) Viewed 3887 times
l_IMG_2319.JPG
Test-fit of sub-packs (1) and (2).
l_IMG_2319.JPG (89.47 KiB) Viewed 3887 times
m_IMG_2353.JPG
I've added charging wires at the top of the box. These will run directly into andersons in the quad-connectors on the power wires, but they will have their own separate 30a fuse, so I can't trip the main fuse from them.
m_IMG_2353.JPG (69.31 KiB) Viewed 3887 times
n_IMG_2355.JPG
The power wires have quad connectors on them, and they are futily plugged into each other instead of a battery pack. Note the fuse and charging wire coming out of the positive connector.
n_IMG_2355.JPG (86.34 KiB) Viewed 3887 times
o_IMG_2356.JPG
I've put an unshrunk heatshrink sleeve around the power wires to insulate them, but mostly to hold them flat against the pack when I try to close the box. Otherwise they would get caught.
o_IMG_2356.JPG (83.92 KiB) Viewed 3887 times
p_IMG_2357.JPG
Sub-Pack (1) installed. Note the negative power wire connected to the negative side, and the positive side is connected to sub-pack (2)'s negative lead.
p_IMG_2357.JPG (75.53 KiB) Viewed 3887 times
q_IMG_2361.JPG
Sub-Pack (2) installed, note the positive side is connected to the circuit breakers, which will slide into the gap above the packs.
q_IMG_2361.JPG (70.5 KiB) Viewed 3887 times
r_IMG_2365.JPG
Sub-Pack (3) installed. It is all a rather tight fit. Note the heatshrink sleeve in the front, that is insulating the positive power wires, that fit into a gap over the battery tabs. From the positive quad connector, note the battery charging wire and fuse that wrap around to the back of the pack. Also on top of the pack you can see the circuit breakers in place. Finally, on the left side, the negative power wires, heatshrink keeping them out of the way so I can close the case.
r_IMG_2365.JPG (88.91 KiB) Viewed 3887 times
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


Image大鸡巴 Motors
Knowledge is acquired through experience, everything else is just information - Albert Einstein
"Cheater?" I'm not competing, I'm Commuting!

User avatar
oatnet   10 MW

10 MW
Posts: 2341
Joined: Apr 26 2007 3:03pm
Location: SoCal, USA

Re: ??????? vs x5403 - Fight!

Post by oatnet » Apr 05 2012 9:18pm

[attachment=12]s_IMG_2371.JPG[/attachment]

[attachment=11]t_IMG_2372.JPG[/attachment]

[attachment=10]u_IMG_2374.JPG[/attachment]

[attachment=9]v_IMG_2375.JPG[/attachment]

[attachment=8]w_IMG_2377.JPG[/attachment]

[attachment=7]x_IMG_2379.JPG[/attachment]

[attachment=6]y_IMG_2383.JPG[/attachment]

[attachment=5]za_IMG_2385.JPG[/attachment]

[attachment=4]zb_IMG_2396.JPG[/attachment]

[attachment=3]zc_IMG_2397.JPG[/attachment]

[attachment=2]zd_IMG_2400.JPG[/attachment]

[attachment=1]ze_IMG_2401.JPG[/attachment]

[attachment=0]zf_IMG_2403.JPG[/attachment]


And finally, my favorite image:


Image
Click here to see the above image in 1920x1200 wallpaper
Attachments
s_IMG_2371.JPG
With the battery complete, I needed to work on the other end of the 4ga cable, and put a quad connector for the controller to plug into, right under the seatpost. This 4ga had (7) twists of wire that were about 12ga each. I put (4) of them into 45a andersons, and cut off three.
s_IMG_2371.JPG (44.3 KiB) Viewed 3884 times
t_IMG_2372.JPG
the back of the quad connector, before I slide up the first heatshrink
t_IMG_2372.JPG (50.72 KiB) Viewed 3884 times
u_IMG_2374.JPG
First heatshrink on
u_IMG_2374.JPG (46.97 KiB) Viewed 3884 times
v_IMG_2375.JPG
second heatshrink on
v_IMG_2375.JPG (41.6 KiB) Viewed 3884 times
w_IMG_2377.JPG
I built up block of (8) connectors to make sure they would fit into the spot under the seatpost, they happened to be red and I think that is why I used them on that first connector. Unfortunately, it was the negative power wire, so I had to cut off the heatshrink, pull off the connectors, and properly cloak them in black as seen here.
w_IMG_2377.JPG (66.16 KiB) Viewed 3884 times
x_IMG_2379.JPG
the power connector, tucked discreetly beneath the seat-post.
x_IMG_2379.JPG (72.02 KiB) Viewed 3884 times
y_IMG_2383.JPG
Both power connectors
y_IMG_2383.JPG (57.27 KiB) Viewed 3884 times
za_IMG_2385.JPG
Both power connectors in their final position
za_IMG_2385.JPG (69.94 KiB) Viewed 3884 times
zb_IMG_2396.JPG
I used 4ga and quad connectors in preparation for using a 144v 500a Kelly controller. They are probably overkill for the 100v100a Methods controller, but I put them on anyway. Here the negative side is done, and I am about to mount andersons on the positive side.
zb_IMG_2396.JPG (88.52 KiB) Viewed 3884 times
zc_IMG_2397.JPG
Another shot
zc_IMG_2397.JPG (58.23 KiB) Viewed 3884 times
zd_IMG_2400.JPG
Both sides heat-shrunk together.
zd_IMG_2400.JPG (59.09 KiB) Viewed 3884 times
ze_IMG_2401.JPG
after plugging the battery and controller quad connectors together, I used heat shrink to seal them up and hold them in place.
ze_IMG_2401.JPG (63.46 KiB) Viewed 3884 times
zf_IMG_2403.JPG
The battery/controller connection in place, over the 9" x 3.5" monster rear shock. I ended up routing a lot of the nuisance connections into a sleeve over the battery wires, for now...
zf_IMG_2403.JPG (94.73 KiB) Viewed 3884 times
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


Image大鸡巴 Motors
Knowledge is acquired through experience, everything else is just information - Albert Einstein
"Cheater?" I'm not competing, I'm Commuting!

MattyCiii   100 kW

100 kW
Posts: 1367
Joined: May 05 2007 2:06pm
Location: Boston, MA, USA

Re: ??????? vs x5403 - Fight!

Post by MattyCiii » Apr 05 2012 10:01pm

oatnet wrote:[The Luminator] TOTALLY rocks. I planned to put a matching one on the right side - now I am not sure I need one.
I'd suggest putting something, anything on the other side, so oncoming cars/cars pulling out of side streets see some width. Maybe "just" a magic shine would do.

Love the great close-ups!
1st build: Dahon Jetstream folding bike. Quick, reliable, capable of 32mph. Light enough to lift, folds for easy transport by car/bus/train.
2nd build: RC powered 2009 Norco A-Line. Top speed 39mph. Built like a tank, it's resistant to Boston potholes, can stop on a dime, easily goes up/down curbs when necessary.
3rd build (just started): Scratch build ultimate utility bike. Based on a common power module using a NuVinci left side freewheel.

User avatar
gensem   100 kW

100 kW
Posts: 1461
Joined: Apr 01 2011 5:28pm
Location: Sao Paulo - Brazil

Re: ??????? vs x5403 - Fight!

Post by gensem » Apr 06 2012 10:21am

My bike looks lika crap compared to your work Oatnet.
Congrats! any videos coming?
Justin we really appreciate what you did!

User avatar
gensem   100 kW

100 kW
Posts: 1461
Joined: Apr 01 2011 5:28pm
Location: Sao Paulo - Brazil

Re: ??????? vs x5403 - Fight!

Post by gensem » Apr 16 2012 5:12pm

Hello Oatnet,

Im trying to order clamps, like the ones you use
http://cgi.ebay.com/ws/eBayISAPI.dll?Vi ... ink:top:en

To test if they better compared to my glued box, but the deal is... I have a couple for DNM Volcano forks that I want to use, but the upper part of the stanchion is 42mm dia. (around 1.64" dia) but im not being able to find a standard clamp that fits.

Do you know about any other clamp manufacturer?
Justin we really appreciate what you did!

User avatar
teklektik   10 GW

10 GW
Posts: 4020
Joined: Mar 26 2011 1:15pm
Location: CT, USA

Re: ??????? vs x5403 - Fight!

Post by teklektik » Apr 16 2012 5:57pm

These are very neat clamps and the folks who sell them (Wehrs Machine) machine these and other goodies themselves. I gave them a ring (easier from the US than Brazil) to see about a custom batch of 6 or 8 made to your spec. They do these in batches and just got done with a run so won't be back at it again for some time. They did say that they would machine some custom reducer sleeves to your exact size for about an extra $5 per clamp assuming about 6-8 clamps. I spoke with "A.J." if you get in touch with them.

Another approach is to order some good quality aluminum tubing and make your own reducer sleeves - just cut the proper width and slit or split the tube so it will collapse a bit when tightened down. You could do this for each clamp or just one long piece per tube. I buy telescoping tubing from DX Engineering in 3 foot lengths (cheap to ship). It looks like their 1 3/4" tubing would be perfect.

Frankly, the extra $5 per clamp is a pretty good buy for a perfect fit...
Visit Grin Technologies at www.ebikes.ca
Build Thread: 2WD Yuba Mundo V4

User avatar
gensem   100 kW

100 kW
Posts: 1461
Joined: Apr 01 2011 5:28pm
Location: Sao Paulo - Brazil

Re: ??????? vs x5403 - Fight!

Post by gensem » Apr 16 2012 7:02pm

These are very neat clamps and the folks who sell them (Wehrs Machine) machine these and other goodies themselves. I gave them a ring (easier from the US than Brazil) to see about a custom batch of 6 or 8 made to your spec. They do these in batches and just got done with a run so won't be back at it again for some time. They did say that they would machine some custom reducer sleeves to your exact size for about an extra $5 per clamp assuming about 6-8 clamps. I spoke with "A.J." if you get in touch with them.
Thats odd... I left a message on ebay this afternoon about the 1.64" dia size and asked for 15 pieces and still no go... He did not offered the sleeves, even tho 5$ would be 75$ just for sleeves...
I will try again see how it goes and report back, just dont plan on doing it myself.
Justin we really appreciate what you did!

User avatar
teklektik   10 GW

10 GW
Posts: 4020
Joined: Mar 26 2011 1:15pm
Location: CT, USA

Re: ??????? vs x5403 - Fight!

Post by teklektik » Apr 16 2012 7:28pm

gensem wrote:Thats odd... I left a message on ebay this afternoon about the 1.64" dia size and asked for 15 pieces and still no go... He did not offered the sleeves, even tho 5$ would be 75$ just for sleeves...
We see how it goes and report back, just dont plan on doing it myself.
Difference was that I called them on the phone :) - they probably only check eBay messages from time to time and will get back to you sometime soon.

You might get a bit better price for 15 pcs (Wow! That's a lot!!) - I didn't ask for that many. They were going to make these up by turning down some thick-walled tubing, so I don't think there is an option to get a smaller number of long adapters made (one for each fork tube) but it might be worth looking into. Also - if you want 15, maybe they would consider jigging up the mill and just making 15 custom clamps in a short run. I can contact them tomorrow for you if you wish.

The size you need (1.64") is just a little off from 1 5/8" (1.625) but it's kind of an odd tubing size, so matching clamps are looking hard to come by.
Visit Grin Technologies at www.ebikes.ca
Build Thread: 2WD Yuba Mundo V4

User avatar
gensem   100 kW

100 kW
Posts: 1461
Joined: Apr 01 2011 5:28pm
Location: Sao Paulo - Brazil

Re: ??????? vs x5403 - Fight!

Post by gensem » Apr 16 2012 7:40pm

teklektik wrote:
gensem wrote:Thats odd... I left a message on ebay this afternoon about the 1.64" dia size and asked for 15 pieces and still no go... He did not offered the sleeves, even tho 5$ would be 75$ just for sleeves...
We see how it goes and report back, just dont plan on doing it myself.
Difference was that I called them on the phone :) - they probably only check eBay messages from time to time and will get back to you sometime soon.

You might get a bit better price for 15 pcs (Wow! That's a lot!!) - I didn't ask for that many. They were going to make these up by turning down some thick-walled tubing, so I don't think there is an option to get a smaller number of long adapters made (one for each fork tube) but it might be worth looking into. Also - if you want 15, maybe they would consider jigging up the mill and just making 15 custom clamps in a short run. I can contact them tomorrow for you if you wish.

The size you need (1.64") is just a little off from 1 5/8" (1.625) but it's kind of an odd tubing size, so matching clamps are looking hard to come by.
I would be glad if you could teklektik, first because phone is much faster, second because english isnt my native language.
So we have 2.54 centimeters in an inch. Right size for 42mm dia of DNM volcano should be 1.653" if you think they could eventually run the milling machine that would be great.

Picture to make sure nothing is missing.
http://www.dnmshock.com/upload_files/fork/usd-180-1.png


Thanks
Justin we really appreciate what you did!

User avatar
teklektik   10 GW

10 GW
Posts: 4020
Joined: Mar 26 2011 1:15pm
Location: CT, USA

Re: ??????? vs x5403 - Fight!

Post by teklektik » Apr 16 2012 8:58pm

gensem wrote:...because english isnt my native language.
Maybe not, but you do really well here on the forum talking to all us SOBs who only have one language :)
gensem wrote:... if you could teklektik...
Picture to make sure nothing is missing.
Sure, I'd be happy to - we'll see what can be arranged with delivery times, etc. and I'll post back here with options.

Picture is Good - thanks. I don't quite understand '15' though. How are all these clamps going to be arranged?

BTW - for any kind of conversion (speed, distance, torque, etc) I use a nifty little free Windows program called Convert. I think I got this 10 or 15 years ago - recommended :D
Visit Grin Technologies at www.ebikes.ca
Build Thread: 2WD Yuba Mundo V4

User avatar
gensem   100 kW

100 kW
Posts: 1461
Joined: Apr 01 2011 5:28pm
Location: Sao Paulo - Brazil

Re: ??????? vs x5403 - Fight!

Post by gensem » Apr 16 2012 10:07pm

teklektik wrote: Maybe not, but you do really well here on the forum talking to all us SOBs who only have one language :)

Sure, I'd be happy to - we'll see what can be arranged with delivery times, etc. and I'll post back here with options.

Picture is Good - thanks. I don't quite understand '15' though. How are all these clamps going to be arranged?

BTW - for any kind of conversion (speed, distance, torque, etc) I use a nifty little free Windows program called Convert. I think I got this 10 or 15 years ago - recommended :D
Your native is the most used language, so I guess you guys are all ok... I said english isnt my main because portuguese is so much easier to me. :)

Fifteen is just a number, I tough about 4 in the small pelicam 1300 and maybe 6 in the bigger 2000 series plus one spare, but its not set on stone, its just a number to make the guy manufacture the clamps.

Btw, enough of this Hijacking... :roll:
Justin we really appreciate what you did!

User avatar
oatnet   10 MW

10 MW
Posts: 2341
Joined: Apr 26 2007 3:03pm
Location: SoCal, USA

Re: ??????? vs x5403 - Fight!

Post by oatnet » Apr 16 2012 10:38pm

gensem wrote:Hello Oatnet,

Im trying to order clamps, like the ones you use
http://cgi.ebay.com/ws/eBayISAPI.dll?Vi ... ink:top:en

To test if they better compared to my glued box, but the deal is... I have a couple for DNM Volcano forks that I want to use, but the upper part of the stanchion is 42mm dia. (around 1.64" dia) but im not being able to find a standard clamp that fits.

Do you know about any other clamp manufacturer?

Hi Gensem!

Have you thought about buying a set of 1.75" clamps, and shimming the .11 difference by wrapping a slice of tire tube or something around the stanchion where it clamps? That was my plan for some larger diameter forks I was considering.

http://www.ebay.com/itm/NEW-WEHRS-MACHI ... _786wt_689

I was planning on using your epoxied-clamp method on my green A-line, I thought you made a great evolution with that technique and wanted to try it. Did you have problems with it?

-JD
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


Image大鸡巴 Motors
Knowledge is acquired through experience, everything else is just information - Albert Einstein
"Cheater?" I'm not competing, I'm Commuting!

User avatar
Alan B   100 GW

100 GW
Posts: 7733
Joined: Sep 11 2010 7:43am
Location: San Francisco Bay Area, USA
Contact:

Re: ??????? vs x5403 - Fight!

Post by Alan B » Apr 16 2012 11:15pm

Did you consider the DX Engineering clamps?

User avatar
teklektik   10 GW

10 GW
Posts: 4020
Joined: Mar 26 2011 1:15pm
Location: CT, USA

Re: ??????? vs x5403 - Fight!

Post by teklektik » Apr 16 2012 11:52pm

That was my first thought but they don't come in 1 5/8" and was a little apprehensive about tightening down a 1.75" U-bolt/saddle that didn't have the proper curvature, particularly because of the large supported weight. Maybe just overly cautious...
Visit Grin Technologies at www.ebikes.ca
Build Thread: 2WD Yuba Mundo V4

User avatar
gensem   100 kW

100 kW
Posts: 1461
Joined: Apr 01 2011 5:28pm
Location: Sao Paulo - Brazil

Re: ??????? vs x5403 - Fight!

Post by gensem » Apr 17 2012 8:36am

oatnet wrote:
Hi Gensem!

Have you thought about buying a set of 1.75" clamps, and shimming the .11 difference by wrapping a slice of tire tube or something around the stanchion where it clamps? That was my plan for some larger diameter forks I was considering.

http://www.ebay.com/itm/NEW-WEHRS-MACHI ... _786wt_689

I was planning on using your epoxied-clamp method on my green A-line, I thought you made a great evolution with that technique and wanted to try it. Did you have problems with it?

-JD
Rubber might be an option but only if he doesnt do a custom run... I mean rubber ll dry with the time and it ll probably sag a little too.

There is nothing wrong with my glued pelicam when used with a single crown fork, aside from the fact that the aluminium base is almost broken (shoulda used a thicker one) I ll remake it in the coming week.
The issue is just the lack of turning angle when you have a double crown fork, also when I was testing, if I push the box even further making a longer adapter to have better fork clearance the lipo box ll shake when you do sharp turns and doing so make the ride dangerous.

I still think the epoxy is very good for single crown, when I do the support again I ll hook it closer to the frame and a little lower.
BTW how and I supposed to remove the DP420 I already have without using heat that could pontencially damage the frame head?

How many kilos do have on your new bigger box?
Last edited by gensem on Apr 17 2012 9:09am, edited 1 time in total.
Justin we really appreciate what you did!

User avatar
gensem   100 kW

100 kW
Posts: 1461
Joined: Apr 01 2011 5:28pm
Location: Sao Paulo - Brazil

Re: ??????? vs x5403 - Fight!

Post by gensem » Apr 17 2012 9:03am

Alan B wrote:Did you consider the DX Engineering clamps?
Not really... Wehrs Machine looked much better that I did not bother
Justin we really appreciate what you did!

User avatar
oatnet   10 MW

10 MW
Posts: 2341
Joined: Apr 26 2007 3:03pm
Location: SoCal, USA

Re: ??????? vs x5403 - Fight!

Post by oatnet » Apr 17 2012 9:22am

gensem wrote:
Rubber might be an option but only if he doesnt do a custom run... I mean rubber ll dry with the time and it ll probably sag a little too.

There is nothing wrong with my glued pelicam when used with a single crown fork, aside from the fact that the aluminium base is almost broken (shoulda used a thicker one) I ll remake it in the coming week.
The issue is just the lack of turning angle when you have a double crown fork, also when I was testing, if I push the box even further making a longer adapter to have better fork clearance the lipo box ll shake when you do sharp turns and doing so make the ride dangerous.

I still think the epoxy is very good for single crown, when I do the support again I ll hook it closer to the frame and a little lower.
BTW how and I supposed to remove the DP420 I already have without using heat that could pontencially damage the frame head?

How many kilos do have on your new bigger box?
On the previous page I have a photo of the finished pack weighing 23.2lbs, and about 4 lbs for the case and clamps, so about 27lbs.

I thought the DP40 was permanent?

Box shake would be a serious issue. Do you experience that in your current setup?

-JD
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


Image大鸡巴 Motors
Knowledge is acquired through experience, everything else is just information - Albert Einstein
"Cheater?" I'm not competing, I'm Commuting!

User avatar
teklektik   10 GW

10 GW
Posts: 4020
Joined: Mar 26 2011 1:15pm
Location: CT, USA

Re: ??????? vs x5403 - Fight!

Post by teklektik » Apr 17 2012 11:21am

teklektik wrote:
gensem wrote:... if you could teklektik...
Sure... I'll post back here with options.
Got in touch with AJ again today. Even at 15 pieces, they can't make a custom run of clamps but they can adjust the price a trifle for making up the adapter sleeves. The normal retail price for the clamp on their site is $12 and they will sell you a clamp + custom split reducer for $13 assuming the 15pc order.

If you want to order these you can do so by email contact@wehrsmachine.com or by ordering normally on-line at their site - in either case, just attach a note (like in PayPal) and make reference to "ATTN: AJ - electric bike - special request for custom reducer sleeves" at the quoted price ($13) and specify the exact inside diameter that you wish. If there are any questions they can ping you by email.

Hope this works out! :D

EDIT - It turns out they will be happy to make these reducers if anyone needs something similar. Contact them by phone and ask for A.J. They may quote a different price, etc, but they seem to be able to turn around the custom reducers in a day or so - outstanding!

>>> oatnet - apologies for this minor thread hijacking, but as a champion of front mounted batteries and these clamps, I didn't think you'd mind too much... :wink:
Last edited by teklektik on Apr 27 2012 12:40pm, edited 1 time in total.
Visit Grin Technologies at www.ebikes.ca
Build Thread: 2WD Yuba Mundo V4

User avatar
gensem   100 kW

100 kW
Posts: 1461
Joined: Apr 01 2011 5:28pm
Location: Sao Paulo - Brazil

Re: ??????? vs x5403 - Fight!

Post by gensem » Apr 17 2012 12:28pm

oatnet wrote: I thought the DP40 was permanent?

Box shake would be a serious issue. Do you experience that in your current setup?
-JD
DP420 is permanent as long as you dont go over a given temperature, but I just cant heat the frame that much because its alum.
Its shaking a little now, but that because the arm is too long its a little beat up due to my friend having a couple accidents with the bike.
I ll think I ll just saw most of the arm and epoxy a new thicker tray that should do.
Justin we really appreciate what you did!

User avatar
oatnet   10 MW

10 MW
Posts: 2341
Joined: Apr 26 2007 3:03pm
Location: SoCal, USA

Re: ??????? vs x5403 - Fight!

Post by oatnet » Apr 17 2012 4:08pm

teklektik wrote:>>> oatnet - apologies for this minor thread hijacking, but as a champion of front mounted batteries and these clamps, I didn't think you'd mind too much... :wink:
No worries tek - on topic as far as I am concerned. :D

I look forward to seeing your new tray Gensem. I'm still mulling over your findings trying to make it work on my other Aline. I guess on the stanchions, you have two hard mounts, but the glued piece is effectively just one.

-JD
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


Image大鸡巴 Motors
Knowledge is acquired through experience, everything else is just information - Albert Einstein
"Cheater?" I'm not competing, I'm Commuting!

User avatar
oatnet   10 MW

10 MW
Posts: 2341
Joined: Apr 26 2007 3:03pm
Location: SoCal, USA

Re: ??????? vs x5403 - Fight!

Post by oatnet » Sep 21 2012 11:50am

A little wheel-build pron...

I got this group-buy 5404 wheelset from JRH yesterday, laced into 19" rims with Deestone 2.50" tires that he bought for my cromotor lace (which I ended up selling to BinLagen instead). The front is a 20mm through-axle for use on Boxxer forks. I only had time yesterday to take them out of the box for this pic and do a quick once-over, but they looked good. Unfortunately, this wheelset is slated for the Green Norco A-line frame, but I'm still working on the Red Frame, so this wheelset will go into storage for the moment.

JRH reports that my 5403, laced in 18" rims with 2.75" Gazelles, will be following shortly - and that wheelset will go on the red Norco frame built out in the previous pages of this thread. When that arrives, we will see progress again on the Red Norco!

-JD
Attachments
5404-19-2.50-IMG_7008.JPG
5404-19-2.50-IMG_7008.JPG (249.57 KiB) Viewed 4469 times
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


Image大鸡巴 Motors
Knowledge is acquired through experience, everything else is just information - Albert Einstein
"Cheater?" I'm not competing, I'm Commuting!

User avatar
sn0wchyld   1 MW

1 MW
Posts: 1754
Joined: Mar 18 2011 8:27pm
Location: South Aus.

Re: ??????? vs x5403 - Fight!

Post by sn0wchyld » Sep 21 2012 5:25pm

oatnet wrote:A little wheel-build pron...

I got this group-buy 5404 wheelset from JRH yesterday, laced into 19" rims with Deestone 2.50" tires that he bought for my cromotor lace (which I ended up selling to BinLagen instead). The front is a 20mm through-axle for use on Boxxer forks. I only had time yesterday to take them out of the box for this pic and do a quick once-over, but they looked good. Unfortunately, this wheelset is slated for the Green Norco A-line frame, but I'm still working on the Red Frame, so this wheelset will go into storage for the moment.

JRH reports that my 5403, laced in 18" rims with 2.75" Gazelles, will be following shortly - and that wheelset will go on the red Norco frame built out in the previous pages of this thread. When that arrives, we will see progress again on the Red Norco!

-JD
looking good!
whats the weight like? particularly with that front tire...

User avatar
oatnet   10 MW

10 MW
Posts: 2341
Joined: Apr 26 2007 3:03pm
Location: SoCal, USA

Re: ??????? vs x5403 - Fight!

Post by oatnet » Sep 23 2012 8:51pm

sn0wchyld wrote:
oatnet wrote: looking good!
whats the weight like? particularly with that front tire...
Weighed them today, the front is 8.6 lbs, and the rear is 38.6 lbs. Reminds me of the old Tidalforce wheels, that IIRC were 35+ lbs. I took a longer look at the lacing job, really a work of art, thanks JRH!

-JD
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


Image大鸡巴 Motors
Knowledge is acquired through experience, everything else is just information - Albert Einstein
"Cheater?" I'm not competing, I'm Commuting!

Post Reply