Custom Build -2 Speed RC Motored Cruiser

Aaaalrighty then ...I have called it quits for the day, after a long day yesterday i am beat, got heaps done none the less,
just about wrapped up the battery mounting compartment, all that's need is a lower and upper plate to which 4 threaded rods will be placed in
each corner and tightened to compress and hold the packs in place ...sorry to disappoint
frock fan bois...no duct tape on this build...again :lol:

Here's a heap of pics i took today and yesterday, i think they are all pretty self explanatory, the whole lot has
to come off again, prolly several times, as such its all finger tight and no washes used, before someone
starts asking "why aren't you using washes blah blah blah..." I assemble, break down everything many times, washes
and loctite are only added on final assembly...



Yes...i have altered the mounting bracket, bought it in closer to the seat tube to gain a lil more room, i also ****ed
up the base, KNOWING the counter sinking needed to be on particular side I EVEN CHECKED it twice and STILL
got it wrong aaaaagh...so another base plate first thing in the a.m no biggy really i guess straight cuts & can use the old
base as a template..Welding of the brackets, this went well, i have added shots of the bare welding, scrapped and wire brushed then
a lil work with the die grinder to show the work involved to get the final result, you shouldn't need much attention to decent flowing weld
primer filler will cover most of these with a swipe of knife putty for any 'ruts' still visible.

Next...this morning i tackled what i didn't quite get to yesterday, the means to hold the planned 12 lipos packs, they
will run long ways from front to back as depicted in (pic 11) below they will also be 'two a breast' ie 4 on each layer
3 layers high...



Left to do on this, add another bracket to the lower seat tube, add an additional plate to hold the aluminum panel to the bottom bracket (you may see it drawn in on pic 10 if your eyez are good enough) also will round all the corners of the angle as depicted in (pic 8)
lil 'trimiing and finiahing work on the aluminium plates to even the gaps up ...Prolly a few other things i forgets now...
shall be back with another update tomorrow arvo...later lads..

KiM

No Spkes & Nipples TiLL Monday

@ allen_okc - Cheers for the kind words mate ;-) I would be very apprehensive drilling into cheap china made bicycle frames and bolting on this much power to them WITHOUT any sort of extra bracing, then haha i would be apprehensive bolting a happy time onto a wall mart bike and doing 45mph on it with caliper brakes too...which i have seen alot here doing... I want a strong frame i know will support me and the force i put on it travelling at higher speeds than most bicycles will see, weight ISN'T as big a factor with motored bicycles as it is with manual pedal bicycle, build
them strong and sacrifice some weight if need be....

@Goat Herder- Tru Dat... china bicycle tubing in general is ..."**** "
there are some exceptions i guess, but its same old adage ain't it, you get what you pay for


Since i had to come in to get the dreaded phone call from the Bicycle Shop re:spokes, thought i would have a break, bite
to eat and unload few pics of small job i did on the bike this morning...the final bracket!! (oh...actually, one
veeeeery small bracket remains to be done, mount for rear disk brake caliper..)

As can be seen in pic 4 I have repaired a hole i blew, it was tiny , the lil dot you see on the repair ISN'T the original hole but
the result of a bubble that popped in the weld :-S Would of given it another blat but that was the end of the freakin
welding wire nearly got the frame done on one and a bit rolls!...Seeing the frame is just about complete, thought i would
see where we iz at weight wise, was quite happy to see ~7 kilo the result...with additional bracket for brake caliper, frame
prepped undercoated and painted i think we will hit ~7.5kilo all told (no seat) Considering the wall thickness of the tubing used
and the steel plate for the brackets is 4mm i think we have a pretty damn solid frame and IMHO not too heavy, i will
definitely feel alot safer knowing i have a strong frame under me when i am scooting about at 60km/hr+

Back later with update of afternoons progress...

KiM

Ok...having rubbed the finger prints off my thumb and two
fingers along with colouring the water red with blood I
used to wet sand the aluminum parts, thankfully ALL
aluminum is prepped ready for polishing :wink: ..
SO today...i think i improved my 2 speed mounting
setup... I was concerned with the whole show moving and possibly
elongating the holes in the seat tube, regardless of how much
i tightened down the 3x 10mm bolts on the mount...SO, i took
some 3mm steel plate and did this-->




I knowingly destroyed the 10mm stainless steel bolts & nylocs i used
to hold the plates in place and square, no biggie ill pick up
new ones before final assembly, as a result though, all
above pics the mount is just sitting there not tightened down
as i don't have any 10mm bolts long enough to screw a nut on
even so haha it doesn't have more than a couple of millimeters
sideways movement with the bolts just sitting without nuts on
the bolts! When tightened, the only way it can move is if it
rips the 6x6mm high tensile counter sunk steel bolts out of the
mount...i am well pleased with the outcome.. Take that Rodgah :mrgreen: :lol:

KiM

Thanks for the input... The fact the seat tube is bent, made from 1.2mm walled tube, reinforced top and bottom along with the 3mm side plates now added, it is more than over kill already... The gearbox will pull the 4 mounting bolts before it will twist the seat tube After building 4 e-bikes from scratch and seeing how much twist even the lil 1000watt Unit motors produced on motor mounts i have learned to beef things up a lil to avoid 'redo's ' when the bikes "finished" What you see in the above pics is an example of that ;-) cheers again for your input, please keep coming with the suggestions/questions always welcomed.

KiM

Thankyou Thud, i knew you would answer the questions better than I :: wink::

Thud said:

back to KiM's lovey build... which is about 3k miles from new zeeland

Click to expand...

HAHA you baaaastard ROFL... hows the weather up there in Canada today Thud

FYI: guys i am from Australia not New Zealand...Calling an Aussi a Kiwi is fightin words... LoL...I think we also have more Kiwis in OZ than there are in New Zealand, i think its because we have more sheep here and they are sick of sexxin up the ones in NZ

Thud said:

I know Kim has low opinions of any brushed motors

Click to expand...

Definitely, and that Unite linked to is the same as the two i burnt out in my trike even when rewound with thicker magnetic wire, they are absolute garbage...

allen_okc...I have no probs with you asking questions but i think you need to slow down a little your asking the wrong person the questions, take Thuds advice and join up on Endless Sphere its a wealth of information...

Thanks again for taking the time to 'set' the record straight Thudster ;-)

KiM

No probz at all allen okc ... ;-)

I been busy last few days doing some prep work on the frame.. still needing to attach
spring mounts when i can afford the seat/mounting hardware and dual shock setup i'm wanting, along with a
disk brake caliper mount, OH...and the extra wide bottom bracket i still need to weld in place...when i get
one from ChoppersUS...As such, had to leave the inner seat stays 'ripples' alone... and the rear dropout
not that it really requires alot of attention haha..First picks are with a lil body filler ...



Actually required very little body filler once all sanded down, the above pic was actually all yesterdays goingz onz haha...

Below pics...are what i got upto today ;-)-->



I said i would have a rolling chassis Monday...lil late but as they say, better late than never unfortunately
though no freaking tubes aaaaagh...so i have just popped the tires on the rims anywayz, they are 24x2.5in Maxxis Hookworms -->



Lotsa room for chain ThudSTeR ;-) ... I have bought a disk brake sprocket adapter from Mr Recumpence to fit on the
Sturmey archer too..should be here soon i hope, but i think we can see there looks to be plenty of room ;-)

Next pension check i will place an order for a stem @ Chan Reaction Cycles, shall add some tubes to the
order when i do... I have also asked good ol Matt.P to pick up some bars (same as i have on blue cruiser)
Matt will be dropping them at the powder coaters for ,e also, there they will be sandblasted before podwer
coated in Satin Black... (they are originally chrome bars)

...There is stacks of sanding and painting still to do on the bike, rember the pics you see above is a just a
quick coat of etch prmer after a few coats of primer filler and some wet sanding i think she will be good to
go with some colour......

We aren't doing to bad it does look vaguely similar to the 'plan'
i painstaking and at no expense to the management! drew up LoL...





Well pleased thus far anwyaz :mrgreen:

Back Soon..

KiM