Discussion in 'Motorized Recumbents' started by appye, Oct 6, 2008.

  1. appye

    appye Guest

    Okay, I have finally started putting my Staton outside-drive kit together. It's a Sun EZ-Sport LE recumbent bike. The wheel was put together by wheelmaster with 9 gauge spokes. I will use a solid polyurethane/nylon tire. I will let you know how that all works out after a few weeks riding.

    I started putting it together last night but I had a problem where the gearbox-to-rack bolts seemed a little short. As illustrated in my picture, the point where they mount to the frame is wider than where the bolts that go through the gearbox. Well, I picked up a few more bolts of varying different lengths from the hardware store, so it should go on pretty well this evening.

    Does the gearbox seem like it is mounted a little high to you guys? As it is now, with the eyebolts sitting all the way down, it still seems to want to mount about 4-5 inches above my tire. Seems excessive. I am thinking about cutting those hollow bracket things down so they mount at the inner hole, rather than the one at the edge. Honestly, this whole mounting scheme where the eyebolts just slide (rather than actually thread) into those hollow square bracket things seems like it might be kind of rickety, I guess I will see once things are bolted up tight.

    I also had to cut my own mounting brackets out of that U-bracket thing that the kit normally comes with. Those have both been drilled and cut to spec (by hand with a tape-measure anyway) so that should go pretty quick.

    I am also using a two-speed system similar to kerf's that I will probably just manually shift by hand for now until I get the urge to install a shifter.

    I call this project overkill because I went as far as I could think to go as far as making this thing as durable as possible. My goal is to have a reliable EVERYDAY driver for work and back.

    Huh ... I gotta change my signature pic!

    Attached Files:

    Last edited by a moderator: Oct 6, 2008

  2. DetonatorTuning

    DetonatorTuning Active Member


    good to see you're getting it together.

    you may want to use all thread rod for your cross bolts. you should have enough length to allow your support legs to go straight up. then you fill in the bolt from side to side with washers or conduit spacers to get and hold the gear box in place to align the sprockets.

    you will have to establish the lay out of your support leg lower mounts first, then put the eye bolts in the tops at their lowest setting. now measure the amount you need to cut each leg to get the eyes of the bolts about 1" above the tire. cut the legs, remount with eye bolts and loose mount the gear box on the all thread. position the gear box for chain line, measure for spacers or start filling with washers.

    install the chain, set the tension THEN lock everything down, and check again.

    see i fyou can get some actual pics up, it'll help us help you.

    keep at it, you may get to ride it this yr. yet.

  3. appye

    appye Guest

    Yeah, I will get pics up pretty quick here. I was supposed to work on it this weekend but I was busy reconfiguring a few laptops for someone and did not get the chance. Then of course last night there was gymnastics class for my daughter, so ...

  4. appye

    appye Guest

    Yeah, I will get pics up pretty quick here. I was supposed to work on it this weekend but I was busy reconfiguring a few laptops for someone and did not get the chance. Then of course last night there was gymnastics class for my daughter, so ...

  5. DetonatorTuning

    DetonatorTuning Active Member


    what's the news brudda. you get any progress to report ?

  6. appye

    appye Guest

    Yeah ... I will update you this evening with some pics even! Sorry, been taking this nice and slow. With beer and doobies and stuff.

    Anyway. Right now I am fashioning my tensioner out of skateboard wheels and scrap metal. I am about to cut my lower mount strap from the old GEBE kit to act as the lever.
  7. kerf

    kerf Guest

    For what it's worth, 3/8" grade 8 bolts work better for gearbox mounting. If you would like to use a lesser grade mounting fastener, I have several bent ones that I would be happy to part with.
  8. appye

    appye Guest

    really? So you expect those threaded rods to bend outta shape, huh? Wouldn't have thought of that. I guess I need to rethink my mounting strategies ... Good thing I haven't ridden the thing yet! I had to get something else because the bolts the kit came with were too short. I suppose I can go to a bolt place and get the strongest 3/8 bolts they have.

    Right now I have everything mounted and am working on the tensioner ... At least I was until the Dodger game came on. Skateboard wheels for the rollers seem like they will do the job. Kerf, I am pretty much mirroring your design here for the tensioner because I want to have LOTS of slack left over for moving the chain from one gear to the other.

    This evening I shall plug away at it for a bit after work...

    EDIT: Hmm. I could just put a bunch of nuts back to back to back on the rods to add a bunch of strength ... That way, they are effectively much thicker.
    Last edited by a moderator: Oct 14, 2008
  9. kerf

    kerf Guest

    If it bends shouldn't bother anything until you fix it, fire that thing up and give it a try.
  10. DetonatorTuning

    DetonatorTuning Active Member

    on the outside drive, since the gear box is in over the wheel, can't you get along with 2- 8" grade bolts ?

    you should be able to walk into any Ace hardware and walk out with them for under $1.50 each.

    my threaded rods haven't bent, but they only have about 100mls. on them. that should be about 1000mls of most peoples use. :shock: LOL

  11. appye

    appye Guest

    Hey, now that I think about it, I have been lurking your other threads. Tell me about this "wah wah wah" phenomenon you guys are talking about. I plan on putting in a tensioner and you say it will dampen that ... but what exactly is this?

    Kerf ... so does my skateboard wheel idea sound good to you? They seem pretty "grippy" to the touch so I am thinking they should be okay. Not quite as soft as the rubber chain guide/roller that I have on the bike for the (double length) pedal chain.
  12. DetonatorTuning

    DetonatorTuning Active Member


    the whawhawha is from the chain flopping side to side and back and forth. what happens is for micro pulses the chain goes totally loose then tighter then loose then....
    you get the idea, what happens is you get little load-unloading switches that sound like whawhawha and causes a lurch and a tail wagging.

    the skateboard wheel should work fine.

  13. kerf

    kerf Guest

    What he said. My chain problems were worse with #41 & 1/4" sprockets. The best was with #510H & 1/8" sprockets. The 3/32" track sprockets produce a small amount of this phenomenon but not enough to bother me.
  14. appye

    appye Guest

    Good to know. I am using 410h and 1/8" sprockets. I ran into a problem last night where the skateboard wheels were too wide and rubbed against the tire. Not a big problem though, as I can heat up a knife on the barbecue... Cuts through those things like butter, should do the job.

    Of course, the Dodger game comes on again tonight but I am getting the feeling that I won't have that problem after today.
  15. DetonatorTuning

    DetonatorTuning Active Member

    so,.......................................................................and then.............................................................................................,


  16. appye

    appye Guest

    Funny. Sorry, things have just been hectic these last few days. But I get off in 20 minutes and head straight home to do some serious bike building. Hopefully I will be riding it tomorrow morning.

    Dodgers definately aren't going to be a problem anymore...
  17. DetonatorTuning

    DetonatorTuning Active Member

    well @#*!!#@, just as soon as i............................................................,

    so i ...................................then it ...................................................

    and i called the wife to come get me and just through it in the trunk, then into the corner of the garage.


    you've been riding the whole weekend and are too selfish to stop and share your satifaction and pride.

    which ?

  18. appye

    appye Guest

    lol ...

    I do deserve that. Still not done. I did not not have much energy on friday and ended up being pretty sick all day saturday and so I got to working on the tensioner today. And my two year old helps a lot too by grabbing bolts and tools and placing them neatly in places where I have to look for them. And now she's sick.

    I Carved up some skateboard wheels and they were still not very suitable so I just decided to go get some real rollers from cycle gear. Now I have to figure out just where to mount it. There are some tight clearances to deal with. It is coming along, slowly but surely. NOT SITTING IN THE CORNER OF THE GARAGE!!!
  19. DetonatorTuning

    DetonatorTuning Active Member knew i was just toying with ya , right ?

  20. vegaspaddy

    vegaspaddy Member

    I know how you feel i have 2 master builders to help me, 2 and 5 years old.

    They love building scarecrows at the moment with my bolts, and my 2 year old thinks the nuts are shinny cherrios.... The 5 year old loves my magnet picker up pen thingie and my washers just keep vanishing into thin air..