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Thread: Sachs xtc 125 conversion

              
   
   
  1. #31
    Senior Member Stevo's Avatar
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    I broke ribs before too... hurt for 10 weeks!! How did you do that? You'll be tinkering in the shop before you know it, just in a lil pain is all
    I like your design work so far... similar to my idea, except you incorporated more components into the plates. I made mine more modular to be able to change batteries or other components as different technologies evolve and become available. Looking forward to final results!
    For what its worth, all of the motor weight and stresses will be on the motor's face where the mounting holes are. The second support plate isn't really doing anything as far as supporting the motor, but I understand the concept and that it's needed to support the other components. You may want to beef up the motor mount side plate to a bit thicker material or gusset it up in select places, like where it attaches to the swingarm pivot and the frame.
    Last edited by Stevo; 18 December 2017 at 1218.
    Current rides: '96 Honda Ohlins VFR, '03 Cannondale C440R, '03 Cannondale Cannibal, '06 Yamaha 450 Wolverine 4x4
    Current builds: http://elmoto.net/showthread.php?t=4354

  2. #32
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    Hi
    been in the boulder hall, slipped sideways with my feet without loosing my grip. the cricular motion banged me into a big grip

    As for the bike.
    You are absolutely right with all your tips so far and i guess i mentioned it somewhere above that material thickness is not to be counted atm... i do not want to fiddle with mm here and there unless i decide it to be the final shape... same aplies for length of bolts.. no washers... keep it at a minimum..
    It is true that mostly the first plate takes all the load. But then the complete plates serves just to regain the stability taken out of the frame by removing the ice. The components merely sticking through it, cause they need to go somewhere... not to waste material and weight i try to give each component as many "tasks" as possible to keep the bike somewhat light..
    wish i came up with something more modular and or even lighter but it needs to be street legal.
    Ive been thinking of incorporating a support into the right plate to really take some more of the load (the motor)...something along the lines of how you would secure a part in a lathe... would need to be light and easy to use though...

    guess there will be some more versions coming up

    flo

  3. #33
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    Hi Flo

    Hope you feel better soon.

    Your motor mount sounds fine. The practice is to check clearance with all weight on the suspension including rider ie the typical ride height you will have when using the bike. Your clearance sounds fine, if you have a picture I might spot something but I doubt it. Bikes are nice and simple.

    Cheers

    Tyler

  4. #34
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    Progress at least.
    Well it took some time healing the ribs and then some catching up on my finances but that at least gave me some time to think things over and, i guess it was worth the wait in the end.
    Brainstorming with my toolmaker friend Michael found a real nice solution for the sproket/axle connection. This was kindly reviewed by a friend of Michael who is working as a devellopping engineer of a well known ev-comp. Easy to swap sprokets once worn out and strong enough by a savety factor of roughly 2. CAD shows the principle.
    Of course one has to wait until a gap in production would allow us to use the Hermle CNC-Center at Michaels work.
    Attached Images Attached Images

  5. #35
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    As of today the wait was over and we..well more Michael made the parts
    CIMG0446.jpgCIMG0443.jpgCIMG0450.jpg
    Fits like a glove

  6. #36
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    As i had enough time on my hand during the wait i fine tuned the design of the "craddle" some more.
    Kelly controller and lower Battery will be held in place by those clamps seen in the CAD blow. Left and right movement is prevented through "shape" (best i can explain in english) for ex. the controller is screwed to an alum. plate which is shaped like a + from above so within its cut out it can not move. to the bat 4 strips of glassfiber are glued as wide as the frame/craddle so they contact the clamps sideways while the "nose" or "hook" keeps it frimly down.
    Second pic showing the 3 parts centering and holding the motors backside. The screws will act like the parts u use on a lathe to hold.
    x36.jpgx38.jpg

    Aluminium sheet for this arrived as well so once i have checked final motor position in respect to chain-sag i can start milling those.

    Hopefully updates and thus progress reports will come more freqeuntly again from now on.

    greets
    Flo
    Last edited by flo; 4 Weeks Ago at 0929.

  7. #37
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    Very nice progress Flo. Interesting sprocket mount also. Did you consider using belt drive for clean and quiet system?

    Cheers

    Tyler

  8. #38
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    HI
    belt drive would have meant too much hazzle here in Germany. In order to get it street legal that is, quite strickt laws...
    Swapping engines is simple as long as the new setup is not more powerfull, runs not faster (easy way to ensure brakes still sufficient). everything else is a pia.

    flo

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  10. #39
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    Chipping away

    Hi
    after checking chain clearence yesturday its finally time to make some chips..
    started with first piece - the motor-mount.
    Snug fit as it should be.
    Guess i will ad some lighting holes tomorrow- easy as perfect position is not critical...
    Flo
    Attached Images Attached Images

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  12. #40
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    Another one done

    Hi
    managed to get left side done
    slightly over 2 kg (have to use different scale) so 3,x kg so fare done.
    Right plate already on the mill to get done tomorrow hopefully.
    Then it`s on to the small parts ... treading and assembly

    greetsCIMG0453.jpgCIMG0454.jpgCIMG0455.jpg

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