Cheap Brompton Conversion Kit?

[shemozzle999]

Handmade reinforcing washers from square stock material for SWXK motor:

 

[jerrysimon]

Nice job and now I have seen the pics I understand how they work

Jerry

 

[shemozzle999]

Hi Jerry,

They can go on either side of the fork - I need them to be on the inside on this motor to increase the clearance between the fork and the motor.

You could get 7 sets out of the 250mm length - works out at £1 a set + work time.

 

[patpatbut]

Hi Colin,

What controller box you are planning to use?

Pat

 

[shemozzle999]

Hi Colin,

What controller box you are planning to use?

Pat

Hi Pat,

It is a secondhand Brompton Sparticle kit I bought from forum member superdove it came with a standard 24v controller, I shall be using that or I could replace it with a smaller sized 24v rated KU65 as it can run both sensored or sensorless.

I would never consider pushing more than 250W through the Brompton front forks.

Even 250W is capable of breaking them if you don't ensure a perfect fit of the motor hub into the forks.

Regards, shemozzle999

 

[patpatbut]

Hi Colin,

In that case, running 36v 15a with this SWXB motor is too powerful?

Pat

 

[shemozzle999]

Not if you feed the power in slowly. Any sudden burst of power will stress the forks unduly - other members with high power systems have sheared their forks.
If you are going to use high power you need to be constantly aware of the problem and ride accordingly if you don't want to induce failure.
I don't over volt or over current so I am not worried while riding.

 

[patpatbut]

Not if you feed the power in slowly. Any sudden burst of power will stress the forks unduly - other members with high power systems have sheared their forks.
If you are going to use high power you need to be constantly aware of the problem and ride accordingly if you don't want to induce failure.
I don't over volt or over current so I am not worried while riding.

Thanks Colin,

I will be mostly pedalling instead of using the throttle. I believe it should be ok.

You said other members have broken their forks. Do you have any link and photo of those incidents?

Thanks
Pat

 

[shemozzle999]

There is a photo on the forum but I am unable to find it with the search engine.

 

[shemozzle999]

Control cable harness now available singularly on Outrider's Aliexpress shop:

Aliexpress.com : Buy OR06A8/A9/A10 3/4/5 in 1 Mouse Water proof Connector Cable from Reliable wire suppliers on E-CYCLE/ E-BIKE KIT SUPPLIER - OUTRIDER TECHNOLOGY

 

[shemozzle999]

Mounting for battery made with 5mm thick aluminum plate

Trial fit of side entry battery and control box:

 

[shemozzle999]

With the battery in the position shown there is a minor folding compromise - when folding back the forks, before hooking onto the bike the steering tube must be dropped as the hinge lever is inaccessible in the fully folded position.





It fully folds with or without the battery attached.





This problem can be overcome by moving the battery (back towards the saddle) to the position as shown below to clear the problem.





The controller box is fine but requires longer M4 screws to fit the slightly larger diameter of the steerer but the plastic clamp can accommodate it and the self tapers supplied to close the lid are too long and require shorter ones.

All that said, it offers an alternative set up that doesn't require the use of a front bag, keeps all the wiring short and folds down to the original Brompton size if the battery is removed from it's base.

 

[patpatbut]

Hi Colin,

How long did you use for M4 screws? I will be getting the same controller box from BMSbattery next week.

Thanks
Pat

 

[shemozzle999]

Hi Colin,

How long did you use for M4 screws? I will be getting the same controller box from BMSbattery next week.

Thanks
Pat

Hi Pat,

I replaced the M4 x 12mm pan hd with M4 x 20mm csk hd.

 

[shemozzle999]

Preparing a KU65 controller for re-wiring.
Noted and recorded existing wire positions and then removed original wiring from board.

When cleaning out the pcb holes with desolder braid I use ChipQuik flux to aid solder take up.







Cleaned off flux residue both sides with pcb cleaning fluid using an old toothbrush - now ready for re-wire.

 

[banbury frank]

Hi A tip for re soldering in new cables if you just strip them and try to fit in the holes you will get whiskers off wire you cant see and short out

So strip about 12 mm long the twist and tin the cable then cut to about 4mm they will fit better and you wont get the odd strand shorting out also the solder will flow through both sides off the PCB as some time the track is only connected on one side so though you solder the rear side the connection can be on the front only

Hope this Helps

Frank

 

[shemozzle999]

Control cable harness now available singularly on Outrider's Aliexpress shop:

Aliexpress.com : Buy OR06A8/A9/A10 3/4/5 in 1 Mouse Water proof Connector Cable from Reliable wire suppliers on E-CYCLE/ E-BIKE KIT SUPPLIER - OUTRIDER TECHNOLOGY

Cici from Outrider has kindly sent me link for a detail drawing showing the construction lengths of the 3-4 or 5 wire harness and can also provide pre-wired kits including brakes, throttle, display, controller etc.

 

[Johan van der Spoel]

Small update for the record; I tried to fit a crystalyte hub in the fork of my Dahon Mu N360. It went very well, no need to spread the fork.

Still thinking about taking the crystalyte or the tongxin. The crystalyte is quite heavy IMO.

Regards,
Johan

 

[shemozzle999]

Hi Johan,

Thanks for the photographs - good information.

Your Dahon Mu N360 would also be a good candidate to fit a 8fun BSS-01 crank motor.

I have been trying to work out the best geared Dahon to fit one in and came up with the 11 speed hub version only to read that some frames have problems and are subject to a recall in the USA, the N360 was my second choice.

 

[Deleted member 4366]

I wouldn't recommend fitting a crank-drive to a bike with hub gears. The N360 is perfect though.