[Smoker]

The spokes could probably be machined down a specific amount, if you want them perfect.

If you cut them down, do you need to add more threads?

 

[henry]

The spokes could probably be machined down a specific amount, if you want them perfect.

If you cut them down, do you need to add more threads?

My friend trued the wheel up after I built it and he thinks it might be ok!


Got the first part machined... I think it might be the first proper machined part I have ever paid for. (I send a lot of stuff to the machine shop at work but I don't have to pay for it haha)

Told the machinist not to worry about surface finish.

Also...this really isn't going to be remotely close to a YZ85.

 

[Pariah]

Well, colour me subscribed. But you'd better not build another electric bike before I finish the Street Triple, punk!

 

[XxGRYMMxX]

sweet!

 

[henry]

Right so I have been doing stuff but progress has been painfully slow for a while. Simply a matter of me not being able to design my life in a way that allows maximum motorcycle building time. But I will do better!


Bought 400 batteries:

Pulled a transformer out of a microwave that reeked of 2 minute noodles. Cut off the secondary coil and tapped out the remnants with a punch. Cleaned up sharp edges with a file. Rewound with some thick cable. Only a couple of turns for high amperage, low voltage. Heaps of info on the net on spot welders if anyone is interested. Bought a timer kit off ebay and the gun/iron thing.

Looks to be working well but welds aren't that strong, I suspected that my cable wasn't thick enough and I think that is the case. I'll rewind it with some thicker cable and let everyone know once I've got it working properly.

 

[shinyribs]

The Mad Scientist returns! Good to see ya, man.

 

[Smoker]

I understand none of this.

And I love it!!! :knucks:

 

[rex_saugerty]

Im in the process of building slightly different spot welder

 

[henry]

I can't believe how long it's taking me to sort myself out... this battery pack is a mission!

Long story short I'm trying to weld quite thick nickel (0.3mm) to the 18650 batteries so the pack can carry the desired current.

The first microwave transformer powered welder I built wasn't powerful enough so I've now built a welder that is powered by two car batteries and uses a mosfet switch (I didn't build the switch) because apparently there is no substitute for low impedance

If anyone is interested in the setup here is a video, apologies for my mono-tonal drone

https://www.youtube.com/watch?v=0JGhkIIWzxc

 

[henry]

Great to have some expert help. A friend who has used a Orion BMS before is wiring it up for me and checking everything is working as it should.

Should have a wheel going within a few weeks.

 

[shinyribs]

Glad to see you are still plugging away at this :rock:

 

[henry]

Motor is running:

https://drive.google.com/open?id=1sYcvnwCMO7pvkWqAIVBGTSt8TddHQxxq

Just a wheel spinning around but it's good to see some rotations.

 

[henry]

Basic internals of battery housing, getting these pieces routed from 6mm ply. Not a perfect solution but a good start I think. Most batteries hidden for faster modeling speed! Sending cut files away today.

 

[henry]

Cutting unneeded tabs off YZ85 swingarm:

Cutting unwanted drop outs off swingarm

Mocking up new drop outs, disc adapter and brake caliper mount.

 

[a_morti]

Just a thought, if you were cutting the dropouts off anyway, could have gone for a 17" rim. Might have been easier to find, and the spokes.

40hp, specific speed... You after DTT on this?

 

[henry]

Just a thought, if you were cutting the dropouts off anyway, could have gone for a 17" rim. Might have been easier to find, and the spokes.

40hp, specific speed... You after DTT on this?

I want the smaller rim size so that I keep good torque for slow hilly stuff, even though I have the higher torque motor. Hard to know what it will actually be like on steep hills but I'll be sure to report back at the time! I'm guessing DTT is some kind of vehicle certification? This bike will be fully off road but in the future a mini motard would be fun.

 

[a_morti]

Doing The Ton

 

[henry]

Working prototype of battery box nearly complete. This design has been way more fiddly than I thought it would be. Next step with this will be to build an aluminium housing for this. The housing might also protect some other parts like the BMS and controller.

I'm actually starting to plan things out now and I'm going to give myself some time-frames.

 

[henry]

Right, I've given myself until the 17th of April to have this thing running. Well enough that I can ride it on the farm and not die.

It's going to be horrible to look at, the wheelbase will probably be too long and it will be stupidly heavy because of the farmer gauge tubing and plywood holding it together.

I've come to the conclusion that I need a mock-up as soon as possible to see how the hub motor actually performs on steep hills. A nasty looking prototype answers my questions and there's no point wasting time on this farm bike if it can't handle big hills.

Avert thine eyes Smoker

 

[Smoker]

Well, the blue frame is popping. :knucks:

Steep hillclimb video? Definitely down for that!