Middrive eBike Kit

thingiverse

Middrive bike mount kit. https://youtu.be/X48GUK8M_4Q Estimated cost is about 250 USD - no battery This is a remix inspired from TEKTONIC 2 by RotaryDesign. Thanks for the inspiration and testing on your design! Goals 1) Reliable Mid-drive kit capable of commuting (see RotaryDesign's Tektonic2 for a 2 year update) 2) Easy to take off and put on in case I want to not have a motor attached to the bike. With this design it should take less than a few minutes to put on and off. 3) FAST - 4000+ watts 4) Efficient/Quiet 5) Low(ish) cost 7) Ability to not lose functionality of front derailleur in order to use the bike as normal. I did have to make some slight modifications to my front derailleur (chopped a few unnecessary bits off!) to make it work but it still shifts as expected when the whole kit is off (comes off in very little time!) The .stl rods are only included to test fit and show where to cut the grooves. (don't use these in the final design - only use to test fit components) I simply used a Dremel ~1mm width cutoff wheel and a Drill to create the grooves in the rod. You can find a list of ALL components you need to complete this build at the link below! TOTAL Build COST (on 8/12/2020) was about $251.31 (not including battery) https://my.aliexpress.com/wishlist/shared.htm?groupId=100000024321909 Materials List, Cost, and Location (click that Aliexpress wishlist to get everything you need!) FOUR M4x20mm bolts (Countersunk holes for mounting motor 1.75 - Ali) FOUR M4x20mm bolts (Standard water bottle cage bolts - you probably already have these on the bike or laying around 1.30 - Ali) FOUR M5X65mm bolts with M5 nuts - These are holding the whole thing together! (3.78 - Ali) FOUR external retaining rings (circlips) for 12mm shaft (Inner Diameter ~11mm) (2.19 - Ali) 5/16 steel rod (axle for belt tensioner - May remove with some more testing) (7.96 - Ali) FOUR 5/16 ID bearings (skateboard wheel bearings) (3.90 - Ali) TWO 8mm springs for belt tensioner (about 3cm long) (3.90 - Ali) Some plastic standoff spacers I had laying around from TV mount kit. - (you can also use marker lid or any plastic tube that has some structure to it) (free) ONE 190kv 4000w brushless motor: (24-36V 45km/h 120KV Brushless Sensored 6384 Motor on Ali also works and is a little cheaper 49.59 - Ali) The one I used is here...https://flipsky.net/collections/e-skateboard/products/bldc-belt-motor-6384-4000w-for-electric-skateboard Pulley set 1: HTD 5M 16T 16mm wide pulley - chose bore size accordingly to your motor specs (10MM) (5.67 - Ali) HTD 5M 15mm wide 325mm belt (5.25 - Ali) HTD 5M 50T 16mm wide pulley 12mm Bore (13.43 - Ali) Pulley set 2: HTD 5M 20T 21mm wide pulley 12mm bore (6.18 - Ali) HTD 5M 20mm wide 400mm belt: (4.28 - Ali) HTD 5M 60T 20mm wide pulley (28.19 - Ali) Remaining components: FLIPSKY FSESC 6.6 based on VESC6 (66.32 - Ali)https://flipsky.net/collections/electronic-products/products/fs-esc-6-6 12mm mild steel rod (100mm long) (12.76 - Ali)https://www.amazon.com/uxcell-Lathe-Round-Solid-Length/dp/B07KY9GNZY/ref=sr_1_2?dchild=1&keywords=12mm+stainless+steel+rod&qid=1588464686&sr=8-2 4x 6201 2RS bearing (4.55 - Ali) Aluminium chain tensioner (7.00 - Ali) 3/32 chain (5.95 - Ali) cheap servo tester throttle (3.00 - Ali) Freewheel + Adapter - (Ali - 14.00) (you will need to make hole just a bit bigger to fit 12mm) I used..... Freewheel adapter (no hole) - This part was hard to drill straight - recommend using drill press if possible. http://www.staton-inc.com/store/index.php?p=product&id=1863 See parts list at aliexpress wishlist: https://my.aliexpress.com/wishlist/shared.htm?groupId=100000024321909 Servo Thumb Throttle comes from: https://www.thingiverse.com/thing:4270258 Advanced step-by-step assembly instructions included in downloads under Middrive Build Instructions.docx