This thread starts over on the introduction section so I will refer back to the beginning.
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I would like to thank Spinningmagnets for his input. It was his article that attracted me to the idea of installing the motor INSIDE the frame triangle. I found a used cruiser down the cape that turned out to be an aluminum frame electra with fenders.
Attached FilesLast edited by calfee20; 05-27-2016, 07:08 AM. -
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I setup my project in an old barn and used a makeshift car rack for a bike stand.
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Here I am checking how much interference there is with the frame.
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There wasn't too much interference so I decided to dimple the main tube with this rig. I crushed a piece of plywood to pad the underside of the frame and you can see not much of a dent was needed.
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Here is the maximum deflection on the drive line. Spinningmagnets' bike hade a 100mm BB but my bike is a little older so not all things were the same as it had a 68mm BB. I had ordered a 100mm BBSHD just in case a future bike required it. When I ordered my kit I had no idea I would find a used bike that is very close to what I want. Here are also a couple of photos of me making a bushing to fit the 68mm bracket.
Attached FilesLast edited by calfee20; 08-09-2016, 07:03 AM.Comment
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Well I have installed an old rear rack and purchased a piece of aluminum to mount the battery. The handle bars are so wide on this bike the harness is a little short so I will either cut the ends of the bars or replace them.
I will get back in a couple of days with more photos and a progress report.........I really like the motor mounted this way!............calfeeComment
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Very nice!
It's good to see bike models being identified that will allow the Bafang motors into the frame/triangle. I mean, that particular frame doesn't leave much other choice, as the motor would otherwise hang down pretty bad. Of course, cruiser-style bikes aren't really about aggressive, off-road riding.
It would be nice to see it with the crank arms and chainring on, to see if the motor seems a little more discreet and stealthy in the frame.
Otherwise, maybe we'll also see some mountain and fat bike frames being identified that are somehow designed in such a way as to allow the same. I mean, most of the mountain a fat bike Bafang installs seem fine, but some of those guys do mention wanting a "bash guard".
Originally posted by calfee20 View PostLast edited by Christian Livingstone; 05-27-2016, 08:23 AM.Comment
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Yeah, those bars do seem a little wacky, even for a cruiser.
I mean, I had a pretty cool six-speed Schwinn cruiser about 25 years ago, that I bought new and quickly installed some Stingray-style bars onto.
Originally posted by calfee20 View PostLast edited by Christian Livingstone; 05-27-2016, 08:54 AM.Comment
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Yeah, those bars do seem a little wacky, even for cruiser.
I mean, I had a pretty cool six-speed Schwinn cruiser about 25 years ago that I bought new and quickly installed some Stingray-style bars onto.
Originally posted by calfee20 View PostComment
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Nice job on the frame tube rework. That looks like a good technique to control the tube deformation. Cool.Fabrication is fun! Build something today. Show someone. Let them help. Inspire and share. Spread the desire.Comment
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Well I have been busy for a bit especially since I finished the bike.
Here is a photo of the spacer in place and a photo of the battery on a rear rack.
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I bought a piece of .125 Aluminum and cut it to the size of the battery mount. Then with some spacers and nutserts I bolted the whole mess together. I also added a layer of 1/16th rubber between the Aluminum and the plastic mount. Dubious value for the rubber, oh well.
Here is a photo of underneath the mount. You can't see much. I should have been taking photos of the process but as I got involved I forgot. I also have a photo of the wiring from the battery to the motor.
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I didn't solder anything because I have some specialized tools from my time in the auto industry. I used some John Deere butt splices that have sealing glue with built-in shrink tube. They are really a trick. If anyone wants I could take a couple of photos of the butt splices and the crimper I used.
The last two photos are of the handle bar set up and the finished bike. I wanted the thumb throttle on the right like a motorcycle but I have found I almost never use it so I have since put the shifter back on the right and the throttle on the left.
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I didn't realize this bike would be so slick. My first "little" test drive turned into a 15 mile run all around town. I couldn't get the grin off my face. Everyone I show is astounded at the silence of the rig. The BBSHD exposes any flaw in your bike. Some creaks and groans were fixed by tightening the head bearings, having the rear wheel trued and then a new rear cluster and derailleur adjustment. A new seat and some front suspension would be nice but in the meantime I have lowered the front tire pressure to the low side of the recommended range and have been fiddling with the rear seat adjustments. A new seat for my big butt is on the horizon.
I am going places I would never have dreamed of on leg power alone. This bike setup is happy at 20 mph and below. Above that and better brakes and suspension would be needed. I went 25 miles mostly flat terrain and the battery still read 100%. The setup only goes up to 48 volts and I have 52 so that may have something to do with it. I will see how far I can go till the battery dies soon.
I am glad I chose a cruiser for this installation. The bike and the riding position is comfortable and the BBSHD makes up for the inefficiency of the bike........calfee
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