E-bike + carbon frame + 52V. 18650 + BMC motor

[soaresdacosta]

...the work continues.

 

[soaresdacosta]

Hi guys,

Slowly put the bike together.
I bought 40 sapim spokes from "em3ev" with 140mm...I think they are 2mm too long.

Luis.

 

[Jimboyr6]

Nice job i think ur b ok if thay stick out abit,with the hole on inside the rim

 

[soaresdacosta]

Hi guys,

Some parts arrive today...no time lost on put them in place.
Jimboyr6, the problem is, I do not have more thread on the spoke to tight the rim. will see.

Luis.

 

[Jimboyr6]

Oh yes not enough thread left,i see,i had same problems i just kept tighting spokes,
I was wondering how long it be before carbon wrap came out

 

[the12be]

have you tried using a die set to add a longer thread ?

http://www.screwfix.com/c/tools/tap-die-sets/cat831180

just clamp each spoke in a vice put oil on the ends and slowly rock the die over your thread put the spokes in the rim mark off the excess thread with a black pen undo the spokes put the nut back on (leave the nipple nut ON when cutting the spokes so you can reattach the nipple nut on and off ) cut off then take the nuts off and re-spoke the wheel

 

[soaresdacosta]

the12be, you are the man. Thanks a lot. I will try that.

Luis.

 

[soaresdacosta]

Hi guys,

Some parts arrive, and just work a little on the bike.
And put a Christmas tree together.

Luís.

 

[the12be]

did the die work ? and I like the crazy bobs just be aware they don't work in wet weather

 

[hedsik]

24s frock yesss

 

[Wolfeman]

Soaresdacosta,
Thanks for the great build thread. You are building the way I'd like to build if I didn't have so many other responsibilities.... 8) I know it takes time to document, photograph and post, thank you for your time.

 

[Jimboyr6]

Yes that tyre looks nice the way its spread out on ur rim,will it fit in ur frame?

 

[the12be]

crazy bobs are 24" and 26" 2.35 I used 26" 2ply (off road looking at a set of maxxis minion FR 2 ply 26" 2.50)

 

[soaresdacosta]

Hello crew,

the12be, For now, I didn't try the die. I still have 0.5mm of tread on each spoke, and looks good. This bike its for the free time...so no rain.
hedsik, I will go with 72volts of lifepo4 18650. The 24s 10amps "lipo" I have, its sold...gone with the CUBE.
Wolfeman, Thanks for your words. Maybe you can build one, your way in the future.
Jimboyr6 , I take some measurements on the frame, before I buy the rims...I think, I didn't fu...up.

Again, Thanks for the support.
Luis.

 

[soaresdacosta]

Hello guys,

After some holidays, is time to continue the project.
I order some spokes from em3ev (great company) and assemble my front wheel.
Next task, its going to be, the rear wheel assemble...it need some metal fabrication on the dropouts.

Take care,
Luis.

 

[Jimboyr6]

Good to see u back,
Bikes looking good aswell

 

[Wolfeman]

Really stoked to see an update on this project. Thanks for posting Soaresdacosta. Beautiful pics and parts as usual. 8)

 

[soaresdacosta]

Hello crew,

Jimboyr6, thanks...is good to be back. 8)
Wolfeman, thanks for your words.

Im going to enter in a part of the project, that im not happy to...dropouts. I need to design and made some new dropouts. Im thinking in using a company like "BigBlueSaw". In the mean time, I will build my battery box, this time, in aluminium.

Luis.

 

[soaresdacosta]

Hello guys,

I really need to resolve this torque-arms big problem... for better try to take measures, I disassemble the rear swing arm...more to came on this.
In a more easy and fast job, I strait the front wheel...Job well done.

Luís

 

[fechter]

It looks like the dropout will need to be machined or sawed out so the motor axle can fit. Does the factory dropout have a pinch bolt?

What is the diameter of the axle hole in the dropout?
What is the thickness of the flat section on the motor axle?

If the flat is the same as the hole diameter then you might do OK to just make a slot. Otherwise you may need a new part that clamps onto the axle and bolts to the swingarm.

 

[soaresdacosta]

Hello guys,

fechter, thanks for your interest in help.
The hole diameter, is a little bigger than the flat side (2mm). In one side, there is a pinch bolt, and maybe I can compensate with that. In the chain side, there is no pinch bolt.
I was more incline, in a part that clamps to the axle and bolts to the swingarm, like some folks did with the Giant. (Kiwi-dropouts).

Luís.

 

[fechter]

There's been some of those posted before. Here's a few:

https://endless-sphere.com/forums/viewtopic.php?f=31&t=49635&start=50

https://endless-sphere.com/forums/viewtopic.php?f=2&t=22898

https://endless-sphere.com/forums/viewtopic.php?f=6&t=33767&start=50

Google image search page:
https://www.google.com/search?q=pinch+bolt+dropouts&biw=1536&bih=746&source=lnms&tbm=isch&sa=X&ved=0ahUKEwi0z8-Tle3RAhVK_mMKHaMQDk0Q_AUIBygC#tbm=isch&q=pinch+bolt+dropouts+site:+endless-sphere.com&imgrc=_

I would recommend the type with a pinch bolt if you have space. These will resist getting loose the best.

 

[soaresdacosta]

Hello people,

fechter, thanks again for your time.
Just one question. I definitely, go with a system, like the "kiwi-dropouts", and absolutely go with pinch-bolt. What material ? Aluminium ? Its more easy to work with...or steel ?

Luís.

 

[the12be]

Steel think of your axle as a (your bikes volt ?) drill you need to stop it from spinning

http://em3ev.com/store/index.php?route=product/product&product_id=88

hope this helps

 

[soaresdacosta]

Hi guys,

the12be, thanks. Yes I understand.
I think I see some guys using aluminium for the torque arms. I can work with aluminium, but not with steel.

Luís.