Electrical bike, nuggets style...

Discussion in 'Some Assembly Required' started by nuggets, Oct 9, 2017.

  1. nuggets

    nuggets It's all my fault...

    Joined:
    Jul 13, 2010
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    3,502
    Location:
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    I feel your pain. I've got a pile of projects going all the time too. Part of what's delaying this bike build is turning my new garage into a usable shop. It's not going as fast as I would like.
    #61
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  2. Aggrocrag

    Aggrocrag Meat Popsicle

    Joined:
    Jul 2, 2014
    Oddometer:
    98
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    Colorado
    Well, hopefully the shop will be done, and you'll have the buddy bike running for when I come to town soon(ish)!
    #62
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  3. nuggets

    nuggets It's all my fault...

    Joined:
    Jul 13, 2010
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    :fpalm:fpalm:fpalm


    I finally got to work on this thing again... So, I haven't figured out how to hold the battery in place yet, and I just haven't worked on this at all. So, I got started on it again yesterday evening.

    I started by making this mount so I could hold the bike on the bench. It's ugly, but works.
    [​IMG]

    Put some new brakes on it... I got some fancy Magura brakes for it after the cheapo brakes that were on it seized up.
    [​IMG]

    Some KTM hardware to mount the calipers.
    [​IMG]

    Here it is on the bench...
    [​IMG]

    I am still not sure how I will hold the battery, so I worked on the wiring... I got it all tidied up around the seat tube.
    [​IMG]

    Here's the other side with the battery in place.
    [​IMG]

    The side panels extend back past the battery box and cover all the wiring. They are cut to follow the line of the fender.
    [​IMG]
    #63
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  4. waylongway

    waylongway madmax Supporter

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    #64
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  5. nuggets

    nuggets It's all my fault...

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  6. redfishguide

    redfishguide Old Dirt Biker Supporter

    Joined:
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    Location:
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    I bought a HF band saw 7 or 8 years ago and it has performed quite well much to my surprise. Catch it on sale and with a coupon....can be had for close to 200 bucks I think.

    Buck has given it his seal of approval and he wasn't even around when I bought it.

    Jack and Buck
    #66
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  7. nuggets

    nuggets It's all my fault...

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    How does it do with metal?
    #67
  8. waylongway

    waylongway madmax Supporter

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    :deal

    Now you have 2 tools....:clap:clap
    #68
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  9. redfishguide

    redfishguide Old Dirt Biker Supporter

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    That's all I have ever cut with it. Including some pretty heavy steel and even some stainless. I have had mixed luck with H F power tools but I am very pleased with the band saw and figure by now it doesn't owe me nothing.

    I really like the fact that it can be used as a verticle or horizontal. Keeping the blade properly aligned can sometimes be a bit tricky but not a major issue. The stand it comes with kinda sucks but I guess it works well enough. I made a new one for mine and added wheels so I can move it around the shop and get it out of the way when I'm not using it. I read some where on the net that the oil they used was really bad so I put in decent gear oil. I even have had pretty good luck with the blades they sell at H F for it. I do use cutting oil religiously when using it and that's probably why the blades have held up. Also take my time and not push it.

    All in all I have been very happy with its performance....dunno maybe I got lucky for once.

    Jack and Buck
    #69
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  10. nuggets

    nuggets It's all my fault...

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    Thanks, what do you think he added to control the motor speed?

    Good info...

    There's a sears one for sale nearby for $100. Hmmm.... Probably a better buy than the harbor freight saw at $370
    [​IMG]


    Didn't make much progress on the bike tonight. Mostly did some looking and measuring and thinking. Ordered some metal I need for this project...
    #70
  11. waylongway

    waylongway madmax Supporter

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    Buy it.....!!
    #71
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  12. more koolaid

    more koolaid Been here awhile

    Joined:
    Nov 5, 2015
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    449
    Location:
    Bel Air Md.
    I have the 12" version and its the most used power tool I have and use a metal blade for everything.

    Cool bike by the way, can't wait for a ride report
    #72
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  13. nuggets

    nuggets It's all my fault...

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    I sent an email... We'll see. Looks like used is the ticket.
    #73
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  14. nuggets

    nuggets It's all my fault...

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    Well, no bandsaw for me I guess. I'm getting no response on that bandsaw. I'll wait, and one will turn up.

    I miss my metal lathe :(
    I'm watching for another one...

    I figured out one of my issues. Well, the bike's issue.

    A drawing.
    [​IMG]

    I've got some 3/8 thick bar stock scrap. Here's the setup to cut.
    [​IMG]

    So, the angle grinder and cut off wheel plus angle iron for edge guide isn't too accurate.

    I use the sander to clean up.
    [​IMG]

    It's labor intensive with the tools I have, but I eventually get to this. A reasonably square little block in spite of the caveman tools. Did I mention I miss the lathe?
    [​IMG]

    I get creative with the vise grip, so I can make marks in the right spots.
    [​IMG]

    Drill and tap. This little block is 3/8 inch thick, and about 20mm square.
    [​IMG]

    Now I have a threaded mount point for the side cover. I have to make seven more.
    [​IMG]

    I'm ordering some bar stock from McMaster since it will be a lot more quick and accurate than carving up weird shaped chunks of scrap.
    #74
  15. nuggets

    nuggets It's all my fault...

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    @waylongway

    I got some foam to try your idea. It's the pick and pluck foam from a pelican case.

    [​IMG]
    #75
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  16. Salsa

    Salsa Long timer

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    Looks like a good heat insulator to me.

    Don
    #76
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  17. redfishguide

    redfishguide Old Dirt Biker Supporter

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    Last I checked the H F metal band saw is $249 add a 20% coupon or maybe a 25% (if you can find one) and your almost at $200. Also I find I do most of my cuts with the saw in the horizontal position. You will have to square off the blade but cuts are pretty accurate.

    Jack and Buck
    #77
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  18. nuggets

    nuggets It's all my fault...

    Joined:
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    True, I'll leave as much air space as I can.

    Gotcha, I thought we were talking about the 14inch woodworking bandsaw. I think that might be a better fit for what I do.

    No bandsaw for me right now. It's on my tools list, that and a lathe.

    I got three more of the tedious little blocks made, and then I had another idea (see the riveted test piece). If I make 3/8 x 3/8 x 1 in pieces, then I can add a threaded hole, and use rivets to attach the little blocks. That will be easier than keeping track of a bunch of loose blocks. I'll still need a few of the little blocks with the two threaded holes.
    [​IMG]
    #78
  19. nuggets

    nuggets It's all my fault...

    Joined:
    Jul 13, 2010
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    Location:
    Virgina
    Got some metal and drill bits from brown santa.

    I bought myself some metric bits for tap and clearance holes for M5 and M6. I had been getting by with close as in hand grenades bits, but taps work best in the proper size hole it turns out.
    [​IMG]

    [​IMG]

    I got a couple more of these little blocks made.
    [​IMG]

    And I installed them. A few more blocks and I'll be able to mount up and finish the side panel.
    [​IMG]


    I also thought you guys might enjoying seeing my other electric bike. This one is a bought electric cargo bike with a rear hub motor. It's not nearly as fast as the hotrod ebike I am building up, but it's a daily driver and way more practical. It's got some minor mods for lighting, and modifications for towing other bicycles. I tow the kids bikes to school with it in the morning and leave the bikes for them there. They ride the bus to school, then I meet them at school in the afternoon, and we all ride home together. I've got 1000 miles on the cargo bike, mostly from going back and forth to work.
    [​IMG]
    #79
  20. nuggets

    nuggets It's all my fault...

    Joined:
    Jul 13, 2010
    Oddometer:
    3,502
    Location:
    Virgina
    I got back to working on mounting the side panel.

    I decided to make four rivet on threaded mounting blocks. Here's the drawing and the pieces of stock cut to size.
    [​IMG]

    And here they are with all the holes drilled, tapped, and ready to mount.
    [​IMG]

    And I have started mounting the side panel and trimming it down to size.
    [​IMG]
    #80
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