Bike builders that have machine tools/shops

[indian22]

Pete I had a difficult time finding good material to study on the subject. I finally laid the endeavor aside & will get back to it. There is much verbiage devoted to the subject with the primary goal, it appears, of impressing others rather than providing clear understanding.

The impression I have is that refreshing the battery is quite minimal, but it can provide impressive advantages in braking.

Controller wiring and terminology employed to explain the wiring is fuzzy logic or perhaps it's just my befuddled mind.

Have a good read. It can't hurt.


Rick C.

 

[Tony01]

You probably have already decided Tony. Either, neither or one or the other.

I love your hybrid. So simple and clean.

There isn’t enough information online to make a choice. Gonna be a 2-speed to start as the machining is the same for both on the gearset. Need to make sure it works and doesn’t grenade.

It seems that performance hybrids tend toward dual drive setups. I think if I make a hybrid I’ll model it on yours.

And....(snaps fingers!)....Everyone back in the room?
Ok folks, enough off topic ramblings. Let's get on with building bikes.
First up, I need to read up about regen braking on e-bikes. Something I'd like, but not sure it's applicable to my current e-stretch build.

Whaaa... WHAT! E-stretch?

Yep as Rick said it’s not going to help much for replenishing energy. Maybe 5%. What it will do is provide you with a strong brake depending on your motor and controller setup; and you can save a lot of money and time on brake pads and maintenance.

Not all controllers do regen. Some are a single set regen power (2-wire, on/off). Others do variable regen. The connection is the same as the throttle 3 wire: ground, +5v, signal.

Your controller will have a wiring harness with gnd and +5v, and two or three analog inputs for throttle, regen brake, and pedal assist.

Sadly there are no brake levers for variable regen. There was one called the Sketchbrake for around $90 but they stopped producing it. I’ll be using a throttle turned around on the left bar. I heard it was a natural feeling setup. Previously I was using a thumb throttle and my thumb would fatigue frequently.

Also be aware that regen will charge your battery back at a far more significant rate than a charger. My regen approaches 35% of my max power and 80% of the battery’s rated maximum charge power. Your battery needs to be able to handle the higher charge rate.

Mechanical; the build must be direct drive or single speed no freewheels. Same way you’d set it up for engine braking.

Pete I can’t wait to see it.

 

[indian22]

Pete invite Tony over to the board track forum to look at your beautiful Blue Bamboo stretch project, post a tease photo here.

Tony a lot of us old guys just dump whatever we're doing in a thread. I think I've got five builds at least in the Old guys Simplex thread and I know that's confusing but I really don't care! lol

Rick C.

 

[indian22]

I love your hybrid. So simple and clean.

There isn’t enough information online to make a choice. Gonna be a 2-speed to start as the machining is the same for both on the gearset. Need to make sure it works and doesn’t grenade.

It seems that performance hybrids tend toward dual drive setups. I think if I make a hybrid I’ll model it on yours.


Whaaa... WHAT! E-stretch?

Yep as Rick said it’s not going to help much for replenishing energy. Maybe 5%. What it will do is provide you with a strong brake depending on your motor and controller setup; and you can save a lot of money and time on brake pads and maintenance.

Not all controllers do regen. Some are a single set regen power (2-wire, on/off). Others do variable regen. The connection is the same as the throttle 3 wire: ground, +5v, signal.

Your controller will have a wiring harness with gnd and +5v, and two or three analog inputs for throttle, regen brake, and pedal assist.

Sadly there are no brake levers for variable regen. There was one called the Sketchbrake for around $90 but they stopped producing it. I’ll be using a throttle turned around on the left bar. I heard it was a natural feeling setup. Previously I was using a thumb throttle and my thumb would fatigue frequently.

Also be aware that regen will charge your battery back at a far more significant rate than a charger. My regen approaches 35% of my max power and 80% of the battery’s rated maximum charge power. Your battery needs to be able to handle the higher charge rate.

Mechanical; the build must be direct drive or single speed no freewheels. Same way you’d set it up for engine braking.

Pete I can’t wait to see it.

I was hoping for a two speed Tony and school us on the tech of regen. So many battery builders/vendors either don't post any detailed specs or often don't speak English as a first language and tech terms are blurry. Same goes for controller info and battery BMS.

Rick C.

 

[FOG]

FOG,
What wear resistant coating will you use in the cylinder?
My 1979 R80/7 BMW was the last iron sleeved engines. There after they used a nicklesil plating.
Tom

The cylinder already has the typical Chinese chrome plating. I dunno how long it will last, but for $25 Amazon will have another one here tomorrow. Why worry?

Hey Tom, I got these doo-dads in a box of mis-matched gauge blocks.

Hard to see in the pic but they got the Ford logo on them. I don't know about anybody else but I never saw one of those in a Ford! But I did finally find a use for one. I mounted it up on my tool post, used it to find center first, and then backed the cross out the radius I needed to match the OD of my squish cut, and scribed a line. Worked good!

Combustion chamber's next.

You mentioned 1-2-3 blocks the other day and I have a pair that appear to be shop made by a man named Mel.

I never met the man but he made some damn fine blocks!

 

[Tom from Rubicon]

FOG,
I acquired from another Tool and Die Maker's estate a volume of
SHOP THEORY
Henry Ford Trade School (Printed May,1943)
This was one of the apprentice manuals. I will thumb through it today and hope to give a proper name.
I can see it chucked in a collet on the round the center flat used to set a lathe bit height and likely how you are using too. I for lack of such a dedicated tool, use a .500" single lip cutter blank.
Tom

 

[Tom from Rubicon]

FOG, do you have a Christian name?
Anyway I spent some time today doing Boolean searches to find those Ford artifacts and batted zero. Could you take some better resolution photos? I think they were used on height gauges, but could not find anything. On the rectangular, I'm calling it a stem. The two smaller flats, how are they finished. The Ford company was very progressive in meteorology practice. Ford imported the best guage makers like.
https://en.wikipedia.org/wiki/Gauge_block
I think your two artifacts are of a earlier age. I dug thru a 1937 Machinists correspondence book this afternoon.
Another zero. If you ever can't stand having a matched set would you consider parting with one? I'm an old tool junky and you got my fix.
Tom

 

[FOG]

FOG, do you have a Christian name?Tom

Sure do. William Robert Watson III ... which means you could call me Billy Bob 3.0. But no one ever does. Bill's fine. And yeah, I'll give one up. It took years for me to use one. I can't imagine why I'd ever need two. PM me an address?

I've been wondering what this big ol' chunk of aluminum was gonna look like on my little 40cc motor. I think it's gonna be OK.

It's not little ... but once it's finned out and polished up some .....

Gonna need a fat chamfer cut on the top corner. It barely clears the pipe.

 

[Tom from Rubicon]

Looking good Bill, with that expansion pipe your engine should make some major ponies. Looking forward to seeing how you generate the head fins.
Thank-you for your generous offer Bill.
Tom

 

[Tom from Rubicon]

Went for a chilly ride to the post office today, might have made it to 57F to post a birthday card.
Rolled the Flyer back into the shop to asses the next move to mount the Taylar Indian styled tool box.
The under top tube saddle clamp sections threaded 10-32 with two of four screws per side. (over kill?) showing in photo. just clear the external mounting tabs that I asked Dan to Tig on to the ends of the tool box for something to clamp onto. So today I realized 3mm formed top clamp straps would not do using 10-32 SHCS. So I will use a 6061-T6 using the round top section profile.
I hope that makes sense. Tomorrows photo should clarify anything misunderstood.
Tom

.

 

[indian22]

It's looking great. Flat top or radius it will look the part. Do you have a couple of leather spanner wraps to secure all and remain rattle free?

As Sargent Major Willie Pete opined, "Overkill is required if you're to remain un-killed & keep both your momma & Uncle Sugar happy. It also cuts down on my paperwork." He had a million of them, R.I.P.

Rick C.

 

[Tom from Rubicon]

Lid is Indian true round top Rick,
Dan calls it coffin top.
Fair amount of machining done to produce two top clamps Tuesday and hope to finish today. Depends on what SWMBO has lined up. When clamps are done I purchased some meguiar's car polishing compound to see if I can brighten up the powder coat finish.
Tom

 

[fasteddy]

Very nice addition to the bike Tom.

Steve.

 

[Tom from Rubicon]

Took SWMBO to her favorite greenhouse and still managed to turn the top clamps to their final width. Mount in the Bridgeport to spot face, center drill, drill, and counter bore for two 10-32 SHCS per side. Then split into halves on the bandsaw.

Great! The new improver server can't upload my previously uploadable photos. Some one want to tap on the administrators window.
Tom

 

[fasteddy]

Tom,
Click on Reply then when that comes up click on More Options at the bottom right. When that comes up scroll to the bottom and click on Help and leave a message. I wasn't getting message alerts and the next day they showed up.

Steve.

 

[Bikeguy Joe]

Tom- I was reading this thread a bit, and came upon the thing about your wife.
My ex just got done with her cancer treatment and she is "good to go for now"....checking back with the docs in a couple of months, with 6 month follow ups and a lot of tests and things for the rest of her life.
THEN one of my daughters tells me she has a non cancerous brain tumor a couple days ago.

Not trying to one up you, just saying "I feel you brother".
As for the job situation.....it's bullshist, but you know what you have to do and what's important. Too bad they don't.

 

[Tom from Rubicon]

Joe, there is no one upsmanship in these situations. Life is Life.
Pleasure to have you with us again.
Tom

 

[Bikeguy Joe]

Thanks.

 

[Tom from Rubicon]

So I machined the top clamp sections Wednesday and assembled Thursday. Over tightened and broke one of the top clamps, cracking right through the thin web of mounting holes. Went to the hardware store and bought two hose clamps. Not elegant but sturdy. Now I can work on the Indian style rear rack.
Tom

 

[indian22]

Shame Tom but it was a nice piece. I've a kinda' love hate relationship working with aluminum.

Rick C..