Electric BMX Sidehack project

[milly]

Hoorah got the bmx back today I dropped to the blacksmith in October and said take your time ☺️
bracket made, motor on just the sidecar and electrics to sort at the weekend maybe.

[FrankenMech]

That is the same brush motor I used for my E-trike project, 3000 RPM 24V 350W 9.87:1(?) about 300RPM output planetary gear-set. I mounted the motor below the frame, hangs down about as low as the derailleur setup and drives a 22T sprocket just to the inside of the 7-speed cassette on the same 15mm axle adapter. It wobbles more than I like. The two 12V 20AH batteries ride in the rear frame 'triangle' where the rear wheel would run. The controller, breakers, charge port, and main switch, are mounted on a plate on the rear frame above them. I used a 30A circuit breaker for the motor circuit and a 5A breaker for the lights. The main switch is rated 20A at 24V. It will probably never be switched under load unless something catches fire. The motor is fairly well sealed for water but I will add a little shoe glue to the wire entry grommet.

Check the planetary gears for enough lubricant. My motor had a little excessive gear whine in my opinion, so I squeezed some regular waterproof bike bearing grease into the unit. It is much quieter now. The gear housing is not sealed with a gasket or O-ring. The grease may drip out...

I will try to get a picture when finished. My motor mount looks crude compared to yours.

[milly]

Will be good to see a picture of yours FrankenMech. I loosen the wheel earlier to adjust the pedal chain what a faff to sort the wheel out when tightening as soon as wheel nut tightened wheel went stiff where the cones kept self tightening under the sprockets somehow where I couldn't get them.Managed in the end by trial and error of making the other side cone really slack and tightening it and then the wheel nut and eventually got it about right till I can find a stool to sit on some I don't hurt so much.
Slowly working on the electrics but put away till morning when I should have it running before tidying it up after initial trial.

[FrankenMech]

Ahhhh, zip ties, looks familiar...

[milly]

Funny that FrankenMech the first bike of the commercial type that was anygood at its price point was called Izip same type of 24v 250w motor 2x sla's and controller not that far from Zip tie in name ☺️
Well all put together roughly and roadtest done maybe see what bigger motor they got for the next one. Airfilled packaging makes a handy battery case to.

[FrankenMech]

You are a LOT faster than I am at getting things done. I am too sick/unsteady/shaking most days. All I got done yesterday was getting a sandwich, grocery shopping, and picking up some half links $2.25ea and another master link $1.50 for my #410 (1/2 x 1/8") motor chain. The local hardware store was much cheaper than amazon which wanted almost $8 for a half link.

So how fast did it go and why a larger motor? You can change sprockets for more speed etc. What is your speed/power limit over there? It is 20MPH here in Kansass and <1000W power.

What is the silver tube with a black handle and key? Is the controller in the black bag?

I have not followed E-bikes. I just needed a trike for balance and noticed the electric equipped ones were way high $$$$$. Way out of my price point but parts were cheap. Putting together a package and getting everything to work was not easy.

[milly]

Sept 18, 2021 9:44:43 GMT -5 FrankenMech said:

You are a LOT faster than I am at getting things done. I am too sick/unsteady/shaking most days. All I got done yesterday was getting a sandwich, grocery shopping, and picking up some half links $2.25ea and another master link $1.50 for my #410 (1/2 x 1/8") motor chain. The local hardware store was much cheaper than amazon which wanted almost $8 for a half link.

So how fast did it go and why a larger motor? You can change sprockets for more speed etc. What is your speed/power limit over there? It is 20MPH here in Kansass and <1000W power.

What is the silver tube with a black handle and key? Is the controller in the black bag?

I have not followed E-bikes. I just needed a trike for balance and noticed the electric equipped ones were way high $$$$$. Way out of my price point but parts were cheap. Putting together a package and getting everything to work was not easy.

Not sure how fast it will go only went on our little road will try GPS with phone when hit the flat road at top .
The silver thing is the 24v 10ah lithium battery pack which sits nicely in the plastic wrap next to it.
We only allowed 250w and max speed of 15.5mph and no throttle only pedal assist mode but I got throttle over 250w it's classed as a moped or motorcycle depending on speed and needs tax registration insurance and mot.
But should be able to get away with about 350 or 500w which helps on hills.
Been doing all the spare hours to get it sorted as funeral again next week all bits sort of taped together just see how it performs ☺️
Bag under seat holds controller and wiring in.

[FrankenMech]

Thanks! I 'breadboarded' my setup on the kitchen counter next to the microwave. Try that with the SO around LOL.

I don't have any GPS. The calculated max speed should be less than 10MPH.

My work now is getting it all permanently installed on the trike. My setup keeps the controller and wiring out in the open for cooling. The connections are all waterproofed with silicon grease. I don't intend to ride in the rain but one never knows with the weather here. I don't want any moisture induced failures.

I can always assist the motor with the pedals. They both mount to the rear axle with freewheels. Either/or can drive the axle and right rear wheel. I use a thumb throttle setup like I made for my scoot on the right handlebar. I moved the derailleur shifter to the left handlebar along with the bicycle bell and the headlight switch and horn button. I bought a solid brass and metal bicycle bell. The trike came with a crap-looking metal and gray plastic one. My cats hate the bell. The horn is about as loud as most scooter horns and built into the headlight and all work from 18-100VDC.

[milly]

Dammo drive sprocket not engaging this morning whole unit turning, best I put the longer axle on that came with kit and spacers.

[milly]

I set mine up in the bedroom FrankenMech and Yolanda was none of the wisest☺️

[FrankenMech]

Working on getting the rear 'trailer' lights wired up. I am not using turn/brake signals, just the tail and clearance lights so the 12V LED units are wired in series. I have tested them and they are very bright. Once I have the wiring finished and tested I can work on getting the cargo basket installed. I still have the job of getting it out of the house with no doors wide enough. I also need to clear space in the garage for storage and mount the battery charger. Always something to do...

[FrankenMech]

Everything works, Start on the basket and garage tomorrow. My rear wheel is still very crooked. With it spinning under motor drive I can tell it is a faulty rear drive hub. I may ask for a new rear drive wheel.

Have you figured out the drive milly?

[milly]

Not yet FrankenMech been doing other stuff today and got a bicycle to finish off tomorrow and then away for a few days for a funeral get it sorted when back from Southampton area.

[milly]

Finally got round to getting rear wheel off now to sort sprockets and longer spindle

[jackrides]

Frank and Milly, sure would like to see some close ups of motor drive connection to wheel, chain and freewheel Please.