E-Trike Cruiser 1000wat 48ah

I fabricated a completely new springer tube today, cut and welded the two sets of springs before grinding the ends flat, the forks are now how i wanted them I have
put together a few 'before' and 'after' pics to show the difference-->

http://members.ii.net/~aussiejester/index/pictures/Custom_springer_forks_series_pic_6-jpg.jpg

The suspension is ALOT stiffer now and the rebound springs are doing their job, the rockers i also reduced the angle of they are nearly parallel to the ground now this also makes the front ride ever so slightly higher than before. With these now finished to my satisfaction....(well, aside from the dual disk caliper mounts which will have to wait until the calipers are delivered before being made..) I shall move back toward the rear of the frame tomorrow and finish off the seat mount and weld in the motor mount fully...more soon fellas

Kim

OK.. not much to report in the way of work done, i have completed the seat frame structure thing-a-ma-jig (will add pics later) Aside from that im waiting for some 4mm plate ali to be dropped off by a mate to make a slightly wider seat pan to accommodate my ample bent broken butt/pelvis as the one now is still slightly to skinny and sitting on it more than 10 minutes getz uncomfortable aaaanywayz... my bro went out this weekend scouring the kerbside collections around the burbs and picked up among other things a 350watt Unite motor powered scooter. Has everything BUT the battery, i intend using the complete wiring loom will save me ALOT of time making one from scratch it includes the indicators, brake light, horn. charging jack, lights etc etc i will keep the lot in tact and use all the lighting from the scooter :) We were sitting there having a beer..and i got the idea whilst sittin back looking at the scoot to lengthen the body work..cut and shut it width wise to 'skinny it up' slightly, cut a position for the seat and plonk it ontop of the trike, i mocked up a photochop to explain-->

http://members.ii.net/~aussiejester...pringer_forks_series_pic_8+_photochop-jpg.jpg

Now this is not a set in stone thing and probably wont happen this side of the trikes first test runs, the front fairing (collected also from kerbside is from a pocket bike) this is a definite starter and i will have some fun grafting the 2x24volt lights from the scooter into the fairing (something resembling a mid 90s Suzuki GSXR front fairing im thinking :) Although i don't intend doing alot of night riding if i do they will be there PLUS the fairing will allow easy mounting of the LCD panel/speedo etc etc...At th end of the day if it is to be passed of as a "mobility scooter" albeit a very fast one LoL i think the body work will go along way to helping this cause the plastic is VERY VERY light so will add little weight to the build and give me more area to get creative with the 'ol airbrush art hehehe :) I have also thought about using the body work as a mold or plug to make up a fiberglass number will weigh the options up and decide which direction to take at a later date...

My front disk parts are on route from USA delivery time early to mid next week i am expecting, be back with an update then if not before...

Kim
 
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I received the remaining parts required to get the bike completed (minus the Lifepo4) today-->

http://members.ii.net/~aussiejester/index/pictures/ChoppersUS_order_pic.JPG

~5 business days from when order was dispatched :-| ****, i have waited longer to get items from the other side of Australia in the past Australia Post could take a leaf out of UPS's book thats for sure...

Anywayz...lil late in the day for me to get enthused about getting covered in iron filings etc so shall get stuck into fabrication of front caliper mounts first light tomorrow, hopefully have ALL calipers mounted AND hooked up with the spiffy new braided brake housing by end of the day...shall have the hub laced up proooobably next week if i'm not able to organize a trip to the local bike shop tomorrow...

Back soon ladies :p

Kim
 
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Lack of parts...my brothers ICE bike build and the Aussie dollar
crashing have all contributed to the trikes build stalling...TODAY however i got a couple of hours too myself and managed to get the front
caliper adapters fabricated, the springer fork rocker modified to bolt aforementioned bracket to and the calipers mounted and hooked up with the
'blingy' stainless braided cable Deec :: wink :: I also ordered some spokes so as i could lace up the dual disk hub (i did that last night)...only thing
that really went wrong was the inner tube copped some spatter (thus a hole) from the MIG as a result I have a flat tire LoL...no biggy,
i had planned on buying new front slick 3inch tire and tube regardless... as always I have 'documented' the work for those following the build--->

http://members.ii.net/~aussiejester/index/pictures/Custom_springer_forks_disk_brake_pic.jpg

I chose to follow the full size chopper trend and mount the caliper directly
above the front axle. Some may see i changed the original '
'template d' design slightly, the bottom was narrowed to allow room for the joint end on the springer forks tube.

LiL Update



I knocked up a set of handlebars yesterday.
The stem i have been using is from a BMX bike,
the mountain bike handle bars had a too wide
OD to fit into the stem properly so i tinkered
with the idea of reaming them out with the die
grinder THEN i had a the idea to lop off the
lower section of the BMX bars that came with
the stem and attach it to a set of straight MTB
bars, came out alot like this--->

http://members.ii.net/~aussiejester/index/pictures/Custom_trike_handlebars.jpg

Also makes for a more comfortable less stooped
over riding position, i think thy turned out nice
anywayz, will paint them the colour of the
frame when time comes... OH also shortened
the brake cables to (neaten them up a lil i think)

I checked the state of the Lifepo4 pricing on
Ebay last night situation has worsened for us
Aussies :-( ping packs up around $AU1200 :-|
RIDICULOUS IMHO... I cant even get some 'fake'
pings for 700 now the cheapest is up around
800 PLUS delivery :: sigh :: I might have to
bite the bullet for the time being and grab 4 SLAs
till the dollar strengthens and the Lifeopo4s drop
in price, i just cant justify the 1200 dollar price tag
at this point in time, it would leave me penniless if
i splurged out on Lifepo4s now.... I have government
payment of 1400 dollars due mid December, if i go
the slas now ill get the Lifepo4s end of December,
hopefully by then the price has dropped not gone
up more :: sigh ::

For now, i need to make a tractor size seat for the
trike...shall have more on that soon.

Kim
 
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Well... i thought some that have followed this build and contributed to it over recent months might like to see a lil video of my trikes firts run... BIG thanks to Matt (1000watt) for the SLA batteries, shall do me over until Lifepo4s find there way to me ;-)

The video is shot from leaving my garage and a lil run around my block, the first half is all up hill, the only flat road in this video contains the two round abouts and down hill section...Sorry no watts up connected as yet (i have one and will be hooking it up tomorrow...also no speedometer :-( ) Matt did advise me these batteries from new weren't the best but i think they did admirably for my initial run on the trike...I also shall upload some detailed pics of the brake hook up and electrics lil later...

Big thanks to those on the forum that have given me input on this build, it is much appreciated:)

E-trike first run

Charged the batteries up last night so I was able to take some pics of the assembled trike this morning...

http://members.ii.net/~aussiejester/index/pictures/Trike_frame_mark II_series_pic_13.jpg

I think i'll be riding it around for a couple of weeks before i stripz it for powdercoat and chrome though heheee...

Back Laters

Kim
Kim
 
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I knocked up a chain tensioner to keep the chain in place...once bitten twice shy ;-) I scoured my pile of donor bikes and chose the lever brakes from a BMX bike, they also match the color of the stem and pegs :) Using the ali brakes and a gutted cog from a derailleur i came up with this-->
http://members.ii.net/~aussiejester/index/pictures/chain_tensioner.jpg

Applies nice tension to the chain hopefully will keep it on during the gear changes ;-)

ALSO1 I snapped some pics yestrday of my new helmet and speedometer-->

http://members.ii.net/~aussiejester/index/pictures/new_helmet & speedometer.jpg

Nothing too flash but will keep the law off my back, it is compulsory to wear helmets when riding bicycles here in Australia...The speedo is a 69 dollar wireless job shall get some close ups of it on the bike laterz...still need to fit the watts up meter, i am waiting on some wire to be delivered from my electrician friend, i want to make a lil 'dash board' up on the handle bars to mount the watts uop and the speedo...back soon folks off for a ride ;-)

Quick lap around the block unfortunately ran out of road before having to slow for round aboutz but managed to top out at 59.5km/hr (36.9m/hr for you backward Americans ;-P ) (thats ~20km/hr over the speed limit on that stretch of road too its a 40km/hr zone LoL)

http://members.ii.net/~aussiejester/index/pictures/speedometer_pics.jpg

I need to find me a loooong flat hill less road where i can use 3rd gear only using 1st (to get up hill) and 2nd before having to slow...trikes still accelerating at this point too LoL..I would think 70 would be easily doable whether i would want to be on it at that speed is another question...might leave that for the test riders LoL...60 is WAAAAY fast enough for me 40 is just fine to be honest... I am also in desperate need for the Maxxis tire i ordered yesterday for the front end too, this knobbly thing is making some BAD vibrations at speed...

Back soon..
 
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I ordered a Maxxis Hookworm 24x2.5 tire for the front wheel of the trike few days ago, got the call this arvo that it was in so had the good ol chook picks it up for me and drops it off, 10 minutes later i was of on a lap of he block for a test...it is 100% improvement on the knobbly front, make next to no noise VERY impressed, think it looks the shizz to :: wink :: ...now just need the 4.25wide 20in rims from ChoppersUS to finish the tire department off ;-)

Couple of obligatory pics of the new tire fitted -->

http://members.ii.net/~aussiejester/index/pictures/Maxxis_hookworm_pics.jpg

My cheap **** Yi-Yun Brand Controller which has already given up the ghost...I'm thinking using an 8amp charge via the controllers 3amp rated charging plug might not have been the best idea...

I Have inquired about freight costs on the following unit (TNC Scooters are disappointingly slow responding still waiting after 36 hours for response)-->

http://members.ii.net/~aussiejester/index/pictures/60VControllerMode HK60.jpg

If i dont hear anything by morning i'll buy via their EBay shop and buy the other items i included on the order from my local scooter shop...(which only sell upto 36volt controllers before anyone asks why i dont get the controller there LoL)

I have also started work on another frame...shall wait till i am further along in the construction before i post pics on that...suffice to say it is lower 'cruiser' look MUCH more "chopper like" if you will...I plan to transfer the forks and trike rear directly onto the new frame HOPEFULLY should be a hassle free change over and completed in a few hours :)

Back Soon
 
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Update

Matt (1000watt on the forum) bought up his lil 60cc ICE cruiser he made to my place few days back-->

http://members.ii.net/~aussiejester/index/pictures/matts_cruiser1.jpg

The craftsman ship that went into this ride is outstanding...thing is schweet ... Matt has also decided to drop his 1000watt
brushless motor into it with a 48v 20ah Lifepo4 :: wink :: will be even better then ;-)

I really liked the low seated position soooo..With that in mind i hit the garage to make something similar

Here's a few pics as i put the frame together --->

http://members.ii.net/~aussiejester/index/pictures/Custom_crusier.jpg

.those with keen eye will notice the incorrect rotation of the rear dropouts :;):
didn't matter in the end the dropouts were notched for the trike conversion to fit into before being welded in place


http://members.ii.net/~aussiejester/index/pictures/Custom_crusier_2.jpg

Lower slightly longer definitely easier for me to get onto :: wink :: i think the lower CG of the bike
will help cornering speeds too.;-)

I will fit the motor and sprockets this arvo and then it will be ready to go (well...ready when i get a new speed controller)

Made up some engine mounts for the frame and bolted the motor in today-->

http://members.ii.net/~aussiejester/index/pictures/Custom_crusier_3.jpg

More Soon :)
 
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I want a set of bars the same as Matt has used on his cruiser (seee above pics)
Matt is checking his local bike store too see if they have another set...They are called
Electra Bars apparently... I did a quick photochop using the bars from the cruiser in above
pics and popped them on the trike to get a 'idea' of how they will look-->

http://members.ii.net/~aussiejester/index/pictures/photochop_Electra brand bars.jpg

Matt said the bars cost around 30-35 bucks...shall wait to hear back on availability
I like the look of them anywayz

The rear suspension wasn't 'sitting' right with me, it appeared
to 'saggy' for lack of better word, i decided lengthening and raising the
rear shock mount would be a simple fix PLUS giving me a little more
ground clearance for the motor side drive sprocket (now has 150mm or 6in. clearance)

I feel better about the 'look' of it now --->

http://members.ii.net/~aussiejester/index/pictures/Custom_crusier_4.jpg

I have also welded a tab on to mouint the chain tensioner...works a treat so
pleased with it ..

NOW..i can get to the fabricating some mounting structure for the seat pan...more soon

Kim
 
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Update



Today i finally tackled the seat mounting affair....
I am using a 'Fat Boy' seat from a mini chopper
(well seat pan @ the moment) that I purchased
for 20 bucks (as a whole covered seat) couple
weeks ago from Movement Systems here in Perth...I
ripped the cover off and used the rubber in it for the
seat on the first trike :-( I shall have a go at
upholstering the pan tomorrow, if this doesn't
measure up to standard i will simply go grab
another seat from Movement Systems seeing they
are only 20 dollars...

I had to make a sturdy base for the pan to sit on...i have
used steel plate for this task (for memory its around 4mm thick)
more than adequate for the job at hand anywayz...I reinforced
the seat tube with a 'X' brace arrangement prior to welding
it onto the base plate....the nylon seat pan then simply bolts
onto this plate....I have slipped a "standardized" size tube
inside the frames upright tube and butt welded it in place...
the seat tube then drops in and is held in place with seat
clamp as per a 'normal' bicycle...heres a few snaps of the
effort--->

http://members.ii.net/~aussiejester/index/pictures/Custom_crusier_5.jpg

I have tested it out (threw a beach towel on the seat pan)
and just as it is it is more comfortable than my previous
efforts, the width is the key here, my broke pelvis requires
support and the seat does the trick ;-) Be even more comfy
when properly padded...The seating position on the bike is
superb VERY relaxed even with the bars, i can only imagine
how 'arm chair' like it will be with the new bars i have
planned ;-)

The fabrication side of the build is now nearly complete (just
realized i need footpegs, shall simply 're-cycle the ones off old
trike
) soooo... aside from hooking up the brakes and
electrics the trike is ready for testing...Hopefully the new
speed controller i have bought arrives sooner than later ...im
hoping around mid next week :: fingers crossed :: Once i
have given it a thorough testing I will handball the frame
off to Matt (1000watt) and he will take ot to be powder
coated...

Update

An old mate dropped round and kept me company whilst i upholstered
my seat pan today... He was kind enough to take some pics of me on the trike...gives
you reprobates a better indication of the size of the trike-->

http://members.ii.net/~aussiejester/index/pictures/Custom_crusier_6.jpg

Yes Yes I know I'm a sexy S.O.B... and ladies YES!!111oneoneone your in luck I'm available :eek: As for the seat... well... it ain't super quality job but it shall suffice for the time being..

More soon fellas..

KiM
 
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Update

Not a huge update today, i fitted the footpegs from the ol' trike and also picked up the 20x1.95in Hookworms
and fitted them to the rear wheels of the trike--->

http://members.ii.net/~aussiejester/index/pictures/Custom_crusier_7.JPG

The 4 SLAs were also re-configured and strapped up with kevlar packing tape to hold them together UNFORTUNATELY
they miss by sitting flat on the bottom tube by a couple of millimeters no biggy really, the Lifepo4s will fit nicely there OR more likely on the frames upright seat tube, with room to spare...

Still know new news on my TNC Scooter consignment which among other things cotains my new 48-60v electronic speed controller...
cross ya fingers fellas i would love it to turn up in a few days ;-)


This post brings
Motoredbikes.com
upto date with the several other forums this work log is on, I shall
continue updating this log here as i progress from this point on ...i'm more than happy to answer
questions that havent been addressed in the worklog already...I hope that those that take the
time to read through my worklog get a lil something from it...& best of luck with your own builds..

More soon...

Kim
 
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