AussieJester
Member
- Local time
- 10:12 PM
- Joined
- Nov 25, 2008
- Messages
- 685
GrrrrAaaagh dear me...i actually made another mount this morning before i started what is reported in the below update, so i have 4 now BUT looks like ill only be using two and be needing a different style mount for front and back of the enclosure :: sigh :: These things are sent too test us John ;-S
Update
Well...i have several things to today, firstly i will start with the battery enclosure..
Yesterday I went too Fiberglass & Resin Sales and picked up some supplies $AU90
later i have 5meters of fiberglass (will need 3 for battery enclosure the rest is for
rear mudguard..and spare) Along with some EcoFoam (expandable foam)
To construct the battery enclosure from. I have also decided NOT too use aluminium for
the sides and top in the construction I will be going with a FULL fiberglass enclosure
Here's a few pics of the progress thus far-->
I have the "rough" shape completed this was done using an old wood saw followed by block & sandpaper.
The scoop height will also be lowered somewhat and the front rounded more...This top section (under the scoop)
will house the ESC and Fechters lil black Box of 'tricks'...Batteries will be below
in a separate section.
Next i will spread some body filler (bondo for you Americans) over the EcoFoam to fill any cracks etc
and basically 'even' things up where needed. The foam will then be sprayed with a few coats of
spray putty and then smoothed over with wet and dry before several coats of
release agent are applied...I should mention now... I WILL NOTbe doing a "traditional fiberglass"
layup, the foam WILL NOT be used as a plug to make a mould from which the finished product
would usuallyge layed up in, I will be covering this foam carving of the enclosure with 3 sheets of 450 chopped glass
this will make it around 3-4 mm wall thickness PLENTY strong enough too house 8
5000ah 22v Turnigy packs(PLUS) along with ESC and Fechters lil black Box of 'tricks'
Once the glass is set, the enclosure will be cut in half (the top lopped off 3/4 way up)
and the foam will be removed leaving a nice sturdy enclosure to glass some 'levels/shelves?' in
for the Turnigy packs to be fasten too along with spots for aforementioned electrics.
Fittings for mounting the enclosure will also be added...The outer shell will then be sanded smooth
and prepared for painting.
Courier called today with a few more parts...
Several weeks ago I ordered a SouthPaw freewheel (left hand thread for the left
hand side of the 3 speed hub) along with an offset sprocket for the Sturmey Archer Extra Wide 3 speed
I was SOOOO relieved when i popped the sprocket in the pulley to find it fit ABSOLUTELY perfect
in the pulley opening, I went by picture of Matt P's Pulley on his1000watt Cruiser worklog as too how much too take out,Matt unfortunately was unable to recall
the diameter he machined in the pulley and as i had no way of finding the measurement of this sprocket it was all guess work...
ZERO SLOP was the result and one happy AJ -->
ALSO!!!! PRAISE THE LORD...The pulley Matt R sent me several weeks ago i thought may have been MIA TURNED UP[/b]!!! I tell you one thing fellas, if you order something from Recumpence and it arrives damaged the courier
will be 110% too blame, the small pulley you see on the reduction drive in picture was in like a
~10in x 10in box PACKED to the hilt with inflatable bags and paper!!! Kudos Matt SUPERB packaging mate
EXTREME overkill in this instance but still SUPERB LoL..cheers mate...
Rear Wheels LACED UP!!!
That knocking you here is Methys knees, hes getting worried
Full GangSTA Status Imminent LoL
The Pulley alignment looks like shes going to be spot on and no further adjustments will need to be made to the
motor mount tubes, shall go ahead and weld these in place in the a.m
Lastly...i also called into Coventry Fasteners on the way to buy the fiberglass yesterday
and picked up the remaining marine grade stainless steel cap screws for the bike-->
These ones are to replace the threaded rod on all but the main actuator pivot..ALL other bolts on the bike
are Marine Grade Stainless steel (with the exception of the actuator main pivot this is front hub axle
i was unable to get a cap screw this length and diameter..)All up around ~$AU60 bucks worth of fasteners
this includes stainless steel nylocs and 2 stainless steel washers on all bolts/nuts...yes its pricey but hey, it looks pro
PLUS! they wont rust and i can disassemble the entire bike with 4 allen keys a shifter and a crank puller
makes for a small tool bag
Will be back tomorrow with an update on the battery enclosure progress...all things going well I shoooould g
have a rough fiber glass enclosure to show you fellas ;-)
KiM
Update
Well...i have several things to today, firstly i will start with the battery enclosure..
Yesterday I went too Fiberglass & Resin Sales and picked up some supplies $AU90
later i have 5meters of fiberglass (will need 3 for battery enclosure the rest is for
rear mudguard..and spare) Along with some EcoFoam (expandable foam)
To construct the battery enclosure from. I have also decided NOT too use aluminium for
the sides and top in the construction I will be going with a FULL fiberglass enclosure
Here's a few pics of the progress thus far-->
I have the "rough" shape completed this was done using an old wood saw followed by block & sandpaper.
The scoop height will also be lowered somewhat and the front rounded more...This top section (under the scoop)
will house the ESC and Fechters lil black Box of 'tricks'...Batteries will be below
in a separate section.
Next i will spread some body filler (bondo for you Americans) over the EcoFoam to fill any cracks etc
and basically 'even' things up where needed. The foam will then be sprayed with a few coats of
spray putty and then smoothed over with wet and dry before several coats of
release agent are applied...I should mention now... I WILL NOTbe doing a "traditional fiberglass"
layup, the foam WILL NOT be used as a plug to make a mould from which the finished product
would usuallyge layed up in, I will be covering this foam carving of the enclosure with 3 sheets of 450 chopped glass
this will make it around 3-4 mm wall thickness PLENTY strong enough too house 8
5000ah 22v Turnigy packs(PLUS) along with ESC and Fechters lil black Box of 'tricks'
Once the glass is set, the enclosure will be cut in half (the top lopped off 3/4 way up)
and the foam will be removed leaving a nice sturdy enclosure to glass some 'levels/shelves?' in
for the Turnigy packs to be fasten too along with spots for aforementioned electrics.
Fittings for mounting the enclosure will also be added...The outer shell will then be sanded smooth
and prepared for painting.
Courier called today with a few more parts...
Several weeks ago I ordered a SouthPaw freewheel (left hand thread for the left
hand side of the 3 speed hub) along with an offset sprocket for the Sturmey Archer Extra Wide 3 speed
I was SOOOO relieved when i popped the sprocket in the pulley to find it fit ABSOLUTELY perfect
in the pulley opening, I went by picture of Matt P's Pulley on his1000watt Cruiser worklog as too how much too take out,Matt unfortunately was unable to recall
the diameter he machined in the pulley and as i had no way of finding the measurement of this sprocket it was all guess work...
ZERO SLOP was the result and one happy AJ -->
ALSO!!!! PRAISE THE LORD...The pulley Matt R sent me several weeks ago i thought may have been MIA TURNED UP[/b]!!! I tell you one thing fellas, if you order something from Recumpence and it arrives damaged the courier
will be 110% too blame, the small pulley you see on the reduction drive in picture was in like a
~10in x 10in box PACKED to the hilt with inflatable bags and paper!!! Kudos Matt SUPERB packaging mate
EXTREME overkill in this instance but still SUPERB LoL..cheers mate...
Rear Wheels LACED UP!!!
That knocking you here is Methys knees, hes getting worried
Full GangSTA Status Imminent LoL
The Pulley alignment looks like shes going to be spot on and no further adjustments will need to be made to the
motor mount tubes, shall go ahead and weld these in place in the a.m
Lastly...i also called into Coventry Fasteners on the way to buy the fiberglass yesterday
and picked up the remaining marine grade stainless steel cap screws for the bike-->
These ones are to replace the threaded rod on all but the main actuator pivot..ALL other bolts on the bike
are Marine Grade Stainless steel (with the exception of the actuator main pivot this is front hub axle
i was unable to get a cap screw this length and diameter..)All up around ~$AU60 bucks worth of fasteners
this includes stainless steel nylocs and 2 stainless steel washers on all bolts/nuts...yes its pricey but hey, it looks pro
PLUS! they wont rust and i can disassemble the entire bike with 4 allen keys a shifter and a crank puller
makes for a small tool bag
Will be back tomorrow with an update on the battery enclosure progress...all things going well I shoooould g
have a rough fiber glass enclosure to show you fellas ;-)
KiM