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  1. K

    Adaptto Mini-E/Max-E Owner's Thread

    I just updated two of my mini-e to the latest firmware and now i have throttle problems. When i go to the "throttle limits" setting menu page I no longer get any movement on the small slider at the bottom of the screen. This with the domino throttle. I have new throttle and have the same issue...
  2. K

    Dedicated E-bike Downhill/Freeride frame and build

    The aluminium parts are all anodized and the bolts are likely to be stainless steel or steel bolts with a special corrosion plating. One of the problems on the prototype has been corrosion of the bolts, but this is easy to fix.
  3. K

    Dedicated E-bike Downhill/Freeride frame and build

    Welding is great way to make bikes (and racecars, my "real" job). For my bike project there is no welding for two major reason. Heat treatment and distortion. When you weld aluminum you lose approx 50% of the strength in the heat affected zone (for typical TIG welding this is the weld bead and...
  4. K

    Dedicated E-bike Downhill/Freeride frame and build

    The swingarm was designed with topology optimization and I was surpized at the number of windows vs pockets. It is CNC machined form 6061-t6 aluminum. I have had a few componet failures in vibe testing but hope to be selling frames and complete bikes soon.
  5. K

    19" Motorcycle Wheels vs 26" Bicycle Wheels (rim and tires)

    Just a FYI I use bicycle spokes and have made custom CNC nipples that fit motorcycle wheels. No washer needed. If there is enough interest I can make them for others.
  6. K

    19" Motorcycle Wheels vs 26" Bicycle Wheels (rim and tires)

    Im running a bridgestone TW301 3 inch x 21 front tire. My rear is a Metzeler Karoo 2 90mm x 21 inch. I prefer the TW301 but the Metzeler distributor is across the street from me so they are easy to get. For this bike the tires are fine but I will be doing a lighter weight build and will need...
  7. K

    19" Motorcycle Wheels vs 26" Bicycle Wheels (rim and tires)

    I dont have very detailed build log. You can see some of the build on my post http://endless-sphere.com/forums/viewtopic.php?f=3&t=50795&p=873172#p873172 here. I have not weighted is but it is around 100 lbs. Its a lot more than I initially planed for but it rides very well. As the components...
  8. K

    Dedicated E-bike Downhill/Freeride frame and build

    New video from todays ride in the mountains. Still a few things to update on the design but it is getting to be alot of fun. I'm not totally happy with the brake feel. I still have not installed the upgraded pads or even switched to the Hope V2's that I have. The Shimano Zee brakes are ok but...
  9. K

    19" Motorcycle Wheels vs 26" Bicycle Wheels (rim and tires)

    Sorry I posted the wrong picture in the last post. Here are the 21's this give you a good before and after look.
  10. K

    Controller mounting inside vs outside

    I use an "inside the box" controller and on my initial prototype I mounted it with double side foam tape. At 5kw the controller easy over heats after 2 to 3 minutes of full power use. I will soon switch to thermal bridge design with the heatsink bridged to the alum enclosure. So in short you...
  11. K

    19" Motorcycle Wheels vs 26" Bicycle Wheels (rim and tires)

    I must be one of the only people running 21's front and rear. OD is only 2mm larger than my old 26 x 2.4 downhill tires. Weight is up big time but I did not measure it back to back. Running Kenda downhill tires my tire life was only 150 to 200km and I was always worried about pinch flats. So...
  12. K

    Hub motor axle mounted in Downhill fork?

    Here is how I did it It only works on an inverted fork however so a DMN, Mantou or DVO....I have a DVO fork on the way.
  13. K

    Cro Motor v2 Dropout Dimensions with 8/9 freewheel

    Obiwan I will modify or machine a BMX style freehub. Its a bit low on my list of things to do however so it will be a few months.
  14. K

    Cro Motor v2 Dropout Dimensions with 8/9 freewheel

    14 is the smallest you can find.....I am working on a 10 or maybe even a 9 but it will be months before its ready.
  15. K

    Caterham Ebikes

    I was a bit surprised to see Caterham make the jump to making e-bike (or at least e-bike prototypes). I had not thought of it much until this afternoon when I noticed my bike hanging out with Caterhams latest(Lola's), the SP300r. I think racecar manufacturers may be one of the surprise new...
  16. K

    Cro Motor v2 Dropout Dimensions with 8/9 freewheel

    a 8/9 or even a 7 speed freewheel will not fit a Cro-motor with a stock axle. If you made a longer custom axle you MIGHT be alright but will likely need to increase the diameter to retain the strength and stiffness.
  17. K

    Anybody try these hills on your e-bikes?

    A few short and steep hill/banks on my commute to and from work. I guess these are around a 45% grade and I cant get up them without a little angle to help me out. But I'm only running 16 for now. W1e9EL-mCFE
  18. K

    Dedicated E-bike Downhill/Freeride frame and build

    Its been along time with no updates for you here on the Sphere...I am done with the design and production of the new frame design and I am doing some durability testing now. This is my new frame design and I may put it into limited production if there is demand. As someone who grew up racing...
  19. K

    How much battery is too much?

    I have 20AH of 32s A123. Good for around 100km on Downhill knobby tires at low speed or more than 60km (my two way commute) with lots of stops and starts and red lights stop speed on my way to work is typically 60kph average of 25-30kph.
  20. K

    The Duty Cycle AWD

    Keep in mind the automotive world has very long product lead times. I think the RAV4 pack was designed in 2008-2009. I am a huge fan of 18650 for large packs, but I don't use them for my 20Ah 100v ebike battery packs yet. There is some complexity that I am not prepared to confront yet. Even...
  21. K

    Dedicated E-bike Downhill/Freeride frame and build

    Its been a while since I posted an update. I am still testing the prototype frame in both 2wd and rwd configurations. I am pretty comfortable so far with the handling. Shock ratio changes and bit shorter swingarm are next. Here are a few photos of the bike from a week ago. I did manage to...
  22. K

    Voltage Limits of electronic components

    I used the MAC 12T motors on 32s A123 set up (around 109Volts). It worked fine. I did not get much time on that setup due to some issues with controllers (self inflicted not a controller problem)
  23. K

    Dedicated E-bike Downhill/Freeride frame and build

    Got the swingarm semi-done. The build on the frame is at a bit of a standstill since I don't have the bottom bracket that i need. It turns out the needed bottom bracket was discontinued about two years ago. I wish i knew that when i specified it for the design. I ordered the needed bottom...
  24. K

    Building a 304 stainless steel ebike frame?

    I occasionally work at a bike frame company that specializes in highend Stainless frames. They dont use 304, is some special alloy Reynolds 953 tubing but I dont know much about the alloy. Remember to passivate it once you are done!
  25. K

    Dedicated E-bike Downhill/Freeride frame and build

    Here is an update. I have most of the frame assembled and picked up the last of the major CNC parts. Since they were late, no time for anodize :(. Its fine since its just a prototype) but my friends here all have nice looking bikes, i gotta try to keep up. Here are photos of the rear shock...
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