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Old 12-25-2021, 03:15 PM   #1 (permalink)
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Electric Bike Fairing Pannier Tailbox LED Lighting System

Progress since my last thread…
• Using Coroplast for fairings, panniers, “pannier/tailbox”, and Tailbox.
• new Cree U7 motorcycle headlights on all bikes
• Lithium Iron Phosphate (LiFePO4) battery has replaced agm.
• acquired ten NOS Sigma Cyclometers at LBS closeout sale…
• Riding much further distance (okay, my health, not technical).
• installed Tannus Armour on one bike, Schwalbe Marathon’s on another
• SJ4000 WiFi has been creating a guide to NYC Bike Lanes
• two bike’s with Photovoltaic Panels

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Old 12-25-2021, 03:27 PM   #2 (permalink)
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Model 318 Construction Photos May 2018

Raw Coroplast corrugated polypropylene

TEST
https://i.ibb.co/2ZkSCPX/IMG-3573.jpg
https://i.ibb.co/v4305Sh/IMG-3574.jpg
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Old 12-25-2021, 03:33 PM   #3 (permalink)
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The ensemble works much more nicely with the Tailbox.
It is tapered to 11° and ends sharply as a Kamm tail, with a vertical row of LED taillights. It is made to follow closely the height and width template of the front fairing.
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Old 12-25-2021, 03:39 PM   #4 (permalink)
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Model 318 with Model 319 Tailbox and LED lights
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Old 12-25-2021, 04:32 PM   #5 (permalink)
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AviationMetalSmith works in Coroplast?
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Old 12-25-2021, 06:00 PM   #6 (permalink)
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Quote:
Originally Posted by freebeard View Post
AviationMetalSmith works in Coroplast?
I’m not sure if you mean ‘does the design work in Coroplast’ or ‘do I work in Coroplast’,
So , no, the design is not as good in Coroplast as it would be in fiberglass. But there’s a long story as to why I had to postpone the fiberglass. Mainly due to the theft of prototype number nine before I could make a mold. Secondarily to finish a working touring bike and cargo bike in a limited amount of time, and that’s actually mainly due to the fact that I feel better off riding a bicycle than working in my workshop.

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My patent application from 1987
Third prototype photo

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My daughter designed the ladies version of the bike, and also the cargo version of the bike , Type 9.


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Easily machined polyethylene for handlebar clamps used a Dremel drill-press stand

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Fifth prototype being tested before the actual ladies version (9th prototype) was built

Last edited by AviationMetalSmith; 12-25-2021 at 06:05 PM..
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Old 12-25-2021, 06:15 PM   #7 (permalink)
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I’ve been criticized for building the front fairing first, and holding off on the rear pannier/Tailbox for later. Actually the front fairing gives me protection so it’s more important. But the rear can carry more weight, and will mount on a standard commercially available rear rack, so I figured it would be easy . This larger Tailbox also has an 11° taper for aerodynamic reasons.

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This is the pattern for the Coroplast. I can cut two of these from one 48” by 96” board, with the front and rear panels being cut from another board. It worked out that way this time, although there is another pannier design cut from one board in one piece (not always possible).
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Old 12-26-2021, 01:06 AM   #8 (permalink)
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Quote:
I’m not sure if you mean ‘does the design work in Coroplast’ or ‘do I work in Coroplast’,
It was a lame attempt at a joke; which I won't explain. Sorry.

You could call it Coroplast Aided Design.
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Old 12-26-2021, 09:09 AM   #9 (permalink)
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Quote:
Originally Posted by freebeard View Post
It was a lame attempt at a joke; which I won't explain. Sorry.

You could call it Coroplast Aided Design.
Non fungible tokens are cool.

Yes, eventually I would like to make the fairings in molded plastic, which would yield better results in terms of compound curves, especially at the edges but also putting a dome or crown on the flat surfaces.

Unfortunately this is not going to work well as an aftermarket item. This fairing only fits one make, model and size of bicycle, and I have installed BMX handlebars because I like an upright position.

Fiberglass is not an ideal choice for mass production either. I would like to use injection molded polyethylene, but I need a machine with 5 axis and 150 ton press.

Also I need to weld the frames or have the frames produced under contract by a bicycle company, with the needed brackets brazed on . Mass production is the only way to make a product inexpensive. (Edit: unless it’s made of Coroplast. But I don’t want to do that. I’d rather publish a DIY Guide.)

And there’s the difference between the touring version and the cargo version. The cargo version has the platform welded to the head tube, the touring version has a fairing on the handlebars.But the rear rack would have the option of being a Tailbox, panniers, or pannier/tailbox.

And there could be a laid-back or dropper seat post.

And I’m leaving room for a rain canopy.

Then there’s the LED lighting; which will cost more than the plastic it’s mounted on. And the solar panels need flat surfaces, so forget what I said about compound curves.
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Old 12-26-2021, 01:48 PM   #10 (permalink)
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A few of the LED lighting photos. I’m satisfied there are no “close calls” while riding at night.

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