Custom Build -2 Speed RC Motored Cruiser

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fasteddy

Well-Known Member
Feb 13, 2009
7,482
4,987
113
British Columbia Canada
KiM, Would you let us know how your mate is doing when you hear. Had a somewhat simular thing happen years ago.

You and your bike continue to inspire. Planning my next e-bike using your suggestions for the battery build.

Steve.
 

KiM

New Member
May 5, 2010
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Australia
Shall pass along well wishes when i can unfortunately i have no contact details for Lawrie dont even know his surname he was one of the fellas attending that didnt pm me his details so i cant ring to see how he's doing im afraid, i only met him for the first time Sunday as did all the other riders. My friends on the ride were Mick, Matt.P and Paul (Timma225) and recently met Jono (HBWC) the others i didn't meet till ride day...Thanks guyz...

KiM
 

KiM

New Member
May 5, 2010
301
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Australia
Some may recal i was having a mate from
Endlesss Sphere Timma2500 (Paul) modify
a standard ali bottom bracket (BB) into an
extra wide bottom bracket to the spec of those
found on ChoppersUS (and required when
extra wide Sturmey Arch hub is used...hence
i need one LoL
) along with lengthening
the axle of a niiiice set of ISIS cranks that
Paul also generously donated to the build ;-)

Paul posted the following pics of the mods in
my worklog on Endless Sphere, i thought i better
post em here too so all know how things came
together rather than just BAM! members check
it out its done! LoL..Heres some very fine shots
Paul took during several stages of the procedure-->



The Axle was cut, sleeved and TiG welded up like the outter BB shell was. An internal sleeve was turned
up on the lathe a step down on each end of this sleeve
to match the axles I.D made the alignment side of
things a breeze, was a case of pressing in the sleeve
and running a weld around the axle, it came out
perfectly true as a result of using this method!

I couldn't have been more happier with the result
I think all will agree he has done an amazing job huge Kudos to Paul for his fantastic work and generosity!

He dropped by yesterday to give me the BB
and i was straight into fitting it up on the bike
and IMO it looks the business!



The Aluminum BB will be anodized blue before
final assembly :) How many ISIS extra wide bottom brackets you see?? how many you seen in
Aluminum mounted on a steel framed bike none
the less! HAS to be a first suuurley loL..

Shall be back with more soon..

KiM
 

KiM

New Member
May 5, 2010
301
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Australia
Cheers Silverbear ;-) I have met a handful of fantastic individuals through the e-bike hobby, it is good to be apart of thats for sure.

Unfortunately i have not heard anything regarding Lawrie's condition but be assured i will definitely post in the worklog the moment i do, his absence from the Endless Sphere forum tends to suggest he might have done some serious injury and possibly be laid up in hospital, as its very strange i thought that he hasn't checked in, i hope for his sake this is not the case, i was next to him, i saw how hard he hit and the angle his body ended up in and i wouldn't be at all surprised if he broke vertebrae in his back.

KiM
 

KiM

New Member
May 5, 2010
301
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Australia
I just got word about Endless Sphere member Lawrie and his condition, a few of you have asked to be updated, well i unfortunately was right, Lawrie has been laid up in hospital flat on his back with crushed vertebra in his lower back and will be this way 24/7 for the next 5 weeks at least...Have sent on well wishes and will keep you guys updated on Lawries recovery.

KiM
 

silverbear

The Boy Who Never Grew Up
Jul 9, 2009
8,325
670
113
northeastern Minnesota
Thanks for the update. That's pretty bad, a crushed vertebrae. When you see him, tell him some guys he doesn't know on the other side of the world in another hemisphere care what happened and are wishing him well. G'day, mate.
SB
 

KiM

New Member
May 5, 2010
301
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Australia
After a couple of tries i managed to get the pivot
mocked up to see if it will all fit in, looks promising-->



^^^ this actually turned out to be scrapped, in favor of a
slightly taller plate, have a small video that shows the
movement of the pivot with new piece, i hope to disassemble
the bike tomorrow drill holes in lower tube and weld
some plates either side of the lower tube that will reinforce
the mount, as per done with the 2 speed mounting arrangement.

Youtube Video Of Pivot/Actuator Working

Another week has passed still no deliveries, will be sending
one last email to the company i bought the seat from and
if i get no reply will open a dispute via ebay hopefully that
will get his attention and some sort of customer service
been 30 days since payment was made for the item, freakin
ridiculous so pissed off.

Back when i have more...

KiM
 

spad4me

New Member
Jan 20, 2008
472
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0
Arizona Bullhead
Beautiful bike as you always build.
Sorry to hear about your friend.
You are not afraid of a crosswind.
I have been blown by a 60 mph crosswind into oncoming traffic when I tried to use a fairing .
I never did that again.
 

KiM

New Member
May 5, 2010
301
0
0
Australia
G'day spad4me, wheres your mate Safe LOL ... yes cross winds are always and issue on fared bikes i guess, this one looks alot bigger than it actually is its really quite small just apears big in pics on its own as often happens i find, heres a pic to show the size when someone is one it, this is my friend Matt.P from Endless Sphere website standing over my bike situated approximately where the seat will be mounted-->



IMO its not what i would consider a 'large' bike...its definatly a midget compared to my cruiser as far as length goes anywayz haha...i doubt i will have issues with wind, this is a bike i'll ride when i feel the urge for some speed, the cruiser will be the daily rider ;-)

Good to see you around spad4me ;-)

KiM
 

corgi1

New Member
Aug 13, 2009
2,272
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KCMO
looks like there is space between the front tire and frame for a large extra, trip extending battery pack
 

KiM

New Member
May 5, 2010
301
0
0
Australia
theres more than enough space in the frame for a 'extended battery pack" ill get 80km with moderate riding and thats more than i will ever use 20km is about my limit before the ass gets sore sitting on the seat.

KiM
 

spad4me

New Member
Jan 20, 2008
472
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Arizona Bullhead
The closeups made the bike look big. The rider in the picture fixes that.

Shhhh You don't want safe posting here.
Between safe and draper there is more useless noise from them relating to electric motorized bicycling.

Always nice to see your builds Aussie Jester.
 

KiM

New Member
May 5, 2010
301
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Australia
I have been holding back on updating this worklog as i wanted all the parts that were
ordered to land .... well... i have had ALOT of deliveries since my last post.. perhaps a few
pics of the goodies -->



Matt.P and I combined our orders together and manged to make the free freight
offered by from Chain Reaction on all orders over $us440 was delivered in 5 days
CR absolutely RoXz no doubt about it.

Keen eyes may see there are more than 2 sets of Hope Mono M4 Brakes :wink:
Big thankyou once again to Recumpence for his continued generosity & support
of my projects... expecting to find a disk brake sprocket adapter when i opened the box from Matt.S
there i was left shocked, starring at mint conditioned set of Hope Mono m4s and a 180mm Saw floating rotor!!!
I tried to order a friend for it from Chain Reaction unfortunately they were out of stock of M4s
so..off to ebay just happened to be a pair of second hand Hope Mono M4s up for grabs, i won them for $US203
cost me 220 to my front door for the pair of Hope Mono M4s in near mint condition! Matt's
will find a home on the front of the bike and one of the second hand jobs will handle the rear
both fitted with Hope braided lines...The third will be a spare until i or one of my cohorts needs
it. Oh...and yes, the Hope calipers will also be receiving some anodized bling Items, damn
Rodgah and Timma2500 pointing out more and more 'bling' that i can buy all
the time curse them both LoL... After chating with Timma yesterday arvo
when he dropped in, seems we both have the same bling and lightening hole "addiction" although
we both admit we can stop when ever we want...yeah right HAHA :p


I asked Matt.P to stand over the bike, this gives a good indication of the bikes
size, pics of the bikes on their own tend to give you the impression they are
bigger than they actually are...Cheers Matt... :wink:


I guess i best tell you all the ending of the seat sagga...as some may remember
33 days IIRC? after payment the seat had made it from Throttle Masters
in Chicago, to UPS in Mexico! After several polite emails to George
at Throttle Masters to which i received no replies, along with Matt.S actually calling them up
and hassling them to get the act into gear OH and a PayPal claims case stared, i finally
received an email yesterday morning from George apologizing for the delay (now 40 something days since payment)
informing me the seat cleared Australian customs yesterday evening! i was
gob smacked i had written it off and was set to buy the second choice seat tomorrow (payday)
I am glad i waited and chuffed it eventually turned up, this seat is just the ticket, suits the bike to a tee.
Still haven't attempted to sit on it though,k looks like it will be ok... :: crosses fingers:: :wink:

So all the parts received have been installed (cept the manual pedal chains...) bought two
cheaper 1/2 links for the manual pedal side need to join them to get the length. My mate
Flavio was also over yesterday, after a few JD's he decided the decals on the rims (and Tires) had to go,
So he pulled the decals off the rims (TPA add "Flavio" to list of helpers LoL) unless the
companies are willing to pay me money to advertise for them, their stickers will find there
way into the bin quick smart :wink: also notice, its rolling on PUMPED UP TIRES!!
(Lettering stillto be removed)

I shall install the seat fittings and pivot tomorrow (more of my handy
routering of alumnium to come using the lovely gift of milling bits from ES member Valy)
I will be using sealed bearings on the pivot mounted in 10mm ali plate...more
to come tomorrow evening, we are BACK on track.... Manual pedal bike will
be up and running soon as the seat is mounted!!! Matt.P or Paul...available
for a test ride LoL... After the seats mounted up i can finish the stabiliser arms
now i have the tubes/tires pumped up and know the exact ride hieght, with Christmas
shutting alot of places down, i will likely hold off for few weeks on ordering all the
batteries and speed controller<---yes speed controller, amongst the deliveries i
received from Mr Edward Lyen a tester unit, hopefully the hassles i have had finding
the correct order of halls, phase and throttle wires will be thing of the past, i will try
to ride the bike within the capabilities of the Infineon it will have fitted until such times
i get my paws on one of Mr Jeremy Harris's new controllers :wink: ..

Back soon chaps...

KiM

P.S Since there are a few regular readers of this worklog that are into the custom
thing, thought you might all be interested in Timma2500's latest endeavor, Paul will
be pumping out altered downhill frames, i suggest those that aren't familiar with Timma2500's
work checkout his latest effort on a Specialised FSR frame and/or the
custom fabrication on his Norco The work is first class, I expect there will be a few people bashing
at his door to get a custom frame happening. Best of luck with your new business buddy...
 

KiM

New Member
May 5, 2010
301
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Australia
I decided to stick with the more 'traditional' pivot setup rather than getting fancy with sealed bearings
the amount of movement is so slight regular dab of molybdenum grease in the pivot and it will outlast me LoL..anyways
here's some pics of the alumnium pivot assembly i knocked up this afternoon.



I have ~6meters of 15mm rod so i cut a 60mm length and drilled it out with 10mm drill bit, this piece will
be welded into the top tube of the frame a 10mm
high tensile steel bolt through it will complete the
pivot setup. I have used 10mm & 5mm thick alumnium
for the rest of the assembly. Obviously the pieces still need to be cleaned up, polished & anodized blue. I will need to
make another bracket tomorrow, to mount on the seats
rear mounting bolts (which FYI are not lined up they
are1/2in out of alignment :-S
) The lil shockies will then mount to this ali bracket.

Back with more soon...i am off in mates boat to do a bit of fishing first light tomorrow, so will likely not get alot done on the bike unfortunately , so next update will likely be Saturday, Boxing Day i'm off to the drags for a Nitro Funny Car meet looking forward to
that i must say ... :lol:

KiM
 

KiM

New Member
May 5, 2010
301
0
0
Australia
Seat Mounted

I have been fighting both fish AND this seat mounting the last few days now, I didn't notice
before hand but the the rear spring mounting bolts on the seat pan are exactly 4mm out
of alignment, doesn't sound alot right? but that 4mm creates a BiG problem at the other
end of the 4inch shock mounting bracket :-S Interestingly the seat has a quality control
sticker on it, has been signed by the person that made it AND the individual
in charge of "QC" (who obviously needs his ****ing eyez checked)


(middle drilled/tapped hole is for the mounting of a rear reflector/light)

I have used a 10mm thick piece of alumnium to make a bracket that will both 'fix' the
factory bumble on the seat, and allow a narrower footprint for shock mounting. Originally i
had planned to drill directly into the seat stays and mount the shocks, the offset of the
mounting bolts on the seat put paid to that idea, the mounting points on the seat stays would
of both been different as would the shock angles..besides this, the gap between the seat pan
bolts is 7in the distance between seats stays ~6.5in either way, i needed to make
a bracket...

i decided a combination gusset/shock mount setup would be
the best solution, I had planned on a gusset here to both reinforce the seat stays and provide
a mounting point for the planned wheelchair tow hitch assembly as per the blue cruiser has on it.



4mm steel plate was used and DAMN! is it hard steel! best mate Snapper hiked 3 pieces
of similar size from his works dumpster before we went fishing few days ago, it blunted
3 drill bits drilling the freakin holes in it, so NO there wont be 'lightening holes'
at this point, but yes i had planned on a couple, No idea what 'grade' steel it is but its hard.
I have 3 solid tacks holding this gusset/mount in place, i shall fully weld this
along with the reinforcement for the stabilizer pivot mounts tomorrow. I then have just a small
mount for the rear brake caliper to add and its frame prep time babee!

Too hot to mess about re-assembling the bike just for a pedal ride up and down the drive way HiGHSiDE
Hyena so you will just have to wait a lil longer for the powered ride :p

Controller... I have spoken to Mr Lyen on MsN and GWhy will be pleased to hear I
organized a highly modified 12 fet infineon to use until Mr Harris's controller
hits the shelf's, so to speak. Mr Lyen has been given several specific mods to make
that the ThudSteR has recommended i have done, the include the addition of 3077 Fets
(~75v 180amp) a 31v low voltage set up, 25-40 amp batt 100 amp phase
programming, along with raising the value of R43 from 1k to 47k ish to modify over
current cutout. I have also taken possession of a 'tester unit' from Mr Lyen & he
has also including 6 hall sensors of the same variety the bois are using on their sensored
Turnigy setups... THiS TiME MaYBE?!?@?#@!?# For those wondering why? not another
Castle Creations HV160, primarily i want halls on this bike as Jeremy's controllers
are sensored controllers, i want to get it setup so i can make a simple swap of
controllers when the time comes....price had nothing to do with it.

Back soon folkz...

KiM
 
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KiM

New Member
May 5, 2010
301
0
0
Australia
Another hot day in West OZ and we have 4 days of consecutive 40C to come next week apparently :-| So...i have
come in early after completing the welding of the shock mount bracket and thought what the ****, i'll slide
the forks in pop the wheels on and see how the seat looks for height...


couple of custom carbon fiber bobbed fenders front and back and i think the bobber look will be complete :lol:

Good news is the height is doable, i should have no issues getting onto the bike, i have my doubts about
the seat being comfortable for me despite two people seating on it and telling me its very comfy! The seat
positioning is perfect arms are outstretched and slightly bent when holding bars (with back straight) Should
be a comfy ride as far as seating position goes, pedaling will likely result in loss of teeth when knees hit chin
buuuut i don't think this will reeeeeally worry me alot :p

Off to a pool parte'/bar-b-q just awaiting my lift... Happy New Year to all Motorbicycling member's and their families
and loved ones....I'll be back in 2011...

KiM
 

Jeco

New Member
Sep 13, 2010
73
0
0
Manila, Philippines
Happy New Year to you Kim as well as to your family.

I've been reading some of your build threads, and man you are very good at what you do.

I wish I'll have the skills...and tools as what you have in the future.

Jeco