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Old 02-14-2009, 12:50 AM   #31 (permalink)
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Wow, I am impressed. Wish I had the time, money, tools, shop to do this myself.

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Old 02-24-2009, 09:02 AM   #32 (permalink)
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I've been really sick for the past week and a half.
Yesterday I cut the end off of the bike hub, lathed it down, and made a bushing to weld into the end of it. I then made an adapter to bolt onto the freewheel.



Last edited by captainslug; 02-24-2009 at 03:30 PM..
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Old 02-24-2009, 06:36 PM   #33 (permalink)
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Test fitting the battery rack parts in the frame.

Tacking all of the battery rack parts together at their final spacings.

Next is filling in the welds, sanding the battery slots, and then welding the finished rack into the frame.

Last edited by captainslug; 02-25-2009 at 10:52 AM..
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Old 02-25-2009, 01:48 PM   #34 (permalink)
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The handlebars that came with the frame were trashed. So Kyle gave me these.

Which I cut up and spiced back together to get the height I want.

I also retapped the threads on the frame. Most of them were stripped or distorted.

Last edited by captainslug; 02-25-2009 at 04:23 PM..
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Old 03-02-2009, 04:21 PM   #35 (permalink)
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I have decided to go with a 1kw brushless hub motor rather than use the permanent magnet and chain drive. Making this change will reduce the total weight of the finished bike by up to 30 pounds. It will also free up a great deal of space. Space which I could later use to add another set of batteries that would allow me to double my range.
I will have to custom spoke the hub motor into the rear rim and add holes to it's side casing in order to mount a brake rotor.

That said, my set of five 12volt batteries arrived in the mail today.
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Old 03-02-2009, 05:01 PM   #36 (permalink)
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link up your hub motor source please Good work.
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Old 03-02-2009, 07:10 PM   #37 (permalink)
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Quote:
Originally Posted by MazdaMatt View Post
link up your hub motor source please Good work.
Golden Machinery Ltd.
Service is mostly Engrish. I wouldn't recommend the "Regen" Controller, since it has proved flaky for most people..

90% of my finished bike is going to be made from parts I ordered directly from manufacturers in China, or used Chinese-made components.
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Old 03-02-2009, 07:24 PM   #38 (permalink)
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Were weight & space the main reasons for ditching the PM motor for the hub unit?
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Old 03-02-2009, 07:32 PM   #39 (permalink)
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Quote:
Originally Posted by MetroMPG View Post
Were weight & space the main reasons for ditching the PM motor for the hub unit?
- Weight
- Space
- Servicing
- Noise
- Durability/Weatherproofing
- Part options

The brush motor has a shorter life span. It's also not as resistant to dirt and moisture.
The amount of weight and space saved is tremendous. I have enough room to later make a rack for 9 batteries of this size in the space that is currently holding only 5. Provided I eventually have more controller option I could step the voltage up further, or simply have more amp hours available.
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Old 03-02-2009, 08:17 PM   #40 (permalink)
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Fair enough. Can't say you haven't thought it through.

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