Yes (and I apologize for not posting sooner). *** WARNING. THIS IS LONG AND BORING ***
The Controller: I've settled on Grin's Baserunner-L10, and Yes $220.00 is way too expensive.
Awaiting for some answers from Grin to clarify we can keep our KD218 displays. From what I can tell our displays are as good as it gets and Grin's B&W units not so much, so at $220 downgrading to a black and white display would be a deal breaker.
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Yesterday, I finished installing a twist throttle. It's much better than the 'thumb-breaker', and on the (correct) right side, which was a bit awkward at first. My major goal of making the bike actually cruise at a given speed has been achieved and now, 'Hell bent for leather, or decelerating' have become choices rather than the only modes available.
A couple quick comments on that installation: The &%$#*@ lock mechanism is very &%$#@ difficult to reinstall. I advise to
scroll a line on the plastic bottom plate to show exactly how far forward the battery connector plate must be for the screw to align - then it will only take 10 or 20 tries instead of 50!
You must reassemble the bottom (long) screw first and be sure the stiff wires from the plate are not causing a spatial conflict with the controller.
Also, the ground/ signal wires on the new throttle were incorrect on the cable's plug - which had larger size wires, a better quality plug and about 3 extra feet - so I cut the wires shorter, soldered them correctly and shrink fit wrapped.
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On to the Torque arms: I went with the "Adjustable Angle Torque Arm by hammer-ebikes" from
uk_cycle_spares on ebay.
The (Super cool) seller accidentally left out the secondary arms, so I waited for them to ship. Shipping time was literally months and while I aged like a wine, waiting I decided 'Hmmmmmm, wouldn't a hole in that rack's steel bracket do that ???? So, I to drilled the 3mm steel plates connecting the Axiom Streamliner Disc DLX Bicycle Rack Pannier Carrier and bolted up the (pre-loaded) torque arms. Viola !!!
I told the evil demon trying to spin my hub, 'flex that, you ^%$#@. Demon's dilemma? That short plate is way stronger than the aluminum frame's attachment. So, if it breaks it'll be by shearing the frame attachment, and it was all hopeless anyhow (See more on plan 'B', below).
Did I say I was involved in building rally (and demolition derby) cars? You run it 'till it fails, bulletproof that, then crush the next weak link, bulletproof that and so on. You don't "fix" stuff that breaks, you make it stronger than the next ten weak links, break more stuff and try to destroy everything. Over, and over.
Yes, we crushed the competition. LOL
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My end plan is to fabricate two more small steel plates, w/ longer bolts (using 5mm spacers where required), creating a sandwich eliminating a secondary arm. Let's see how strong that aluminum attachment really is. The other, upper attach points are so ill spaced they're virtually useless and I just can't see them adding any strength, with the spacers required to fit flush.
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To complete the assembly, I used (
Must Have ALERT) "Nord-lock" washers. Not cheap. Well worth it though.
Set-up: Fine spine side facing the aluminum frame> torque arm> second fine side facing torque arm and the coarse facing the R1U's Steel, automotive lug-nut.
A 200mile Inspection indicates zero movement since this installation method.
Note the washers. Pic 163213 shows a stock washer and two Nord-locks (Coarse sides out). That wear you see is how much that stock lock-washer was making contact !!! Same with photo (Stock washer and Nord-lock Fine side out)163109.
Look how little of the contact surface is marred? Really? 100NM of torque relying on that little contact?
Is there any amount one can torque that lug-nut down that could actually improve that situation, perhaps increase the contact surface from it's now unacceptable 20%, to even, say 30% ? The Lug-nut has even (way, way) coarser locking spines. Maybe 10% of it's surface is making contact with the washer. You want weak-link fail, there it is.
I also tried simply using Nord-lock washers, but upon disassembly, comparing to the dots I scrolled I detected movement. Another FAIL.
The torque arm on the derailer side had to be sanded down to eliminate clearance conflicts.
Never mind paint damage. When the hub spun, transporting it home in the back of a Tow truck meant scratches and when we tried to unlock that axle, anything those 1/2 drive tools touched they scratched.
I don't care because if the fix doesn't work and it spins again - with the baserunner pumping 80A Peak Phase Currents (~45-50A Continuous), I'll cut the aluminum dropouts off, weld drilled aluminum plates on and bolt up ballistic steel dropouts. Then when I finish, I'm going to strip and paint the frame in polyurethane and until then a scratch is a broken nail crisis.
IMHO a 40A controller would spin the stock set-up with ease. This motor is putting out maybe half it's rating with the stock controller. "Maybe", if that. 100nm is no joke. 173220 shows what you face - a spun axle. I'm not installing that Baserunner until I have that second plate installed.
The last point: Be sure to pre-load the arm before bolting down.
Visualize the wheel's going forward force pushing the opposite way, rearward, away from the frame. Adjust to tension, removing all slack in that direction and tighten down.
I highly recommend this Streamliner rack for our bikes. It's quality aluminum with steel brackets; heavy black finish; bolts right up and works to mount the torque arms perfectly ... $39
freewheel_bikes_madison on ebay. Even the arms are round steel stock with billet clamps , not cheesy flat steel like the rest - even Tubus.
And again, I cannot stress enough what great seller Ian of
uk_cycle_spares is for the torque arm. Highly recommended and honest. This is buying on the ground floor, direct and exactly what it says it is.
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I've also replaced the stock 44T Chainring and guard ('bash-guard' to me) with a 48T 1048CD, Deckas Narrow Wide Chainring w/ custom, laser-cut (US Made) Bash-guard. Included a few photos below. Compare that ugly stock bash ring - LOL.
If anyone cares, I have full photos and the particulars. If anyone can tell me the name of the company that makes my bash-guard, please do. A custom shop, they seem to have disappeared.
It looks sick, the chain feels far smoother and the new 48 tooth cog, 9% larger than the stock 44 tooth ??? yes, I detect an added 2mph top end pedaling now - 31.5mph.
More on the rest coming: Laser lights/ wireless turn signals; F & R fenders; front racks (two types); HD Ursus double arm kickstand; (various brands) extender bars to mount display/ GoPro/ Lighting; the 20,000 lumen 18650 rechargeable, +11 hours at "a brightness cars will high beam you", detachable LED Headlight, and the ABUS A6000 (attached to the seat tube), which works nice, but (every damn time) is a real pain to open and close without the alarm squealing and you looking like a dolt.
My boomerang GPS tracer is not yet installed.
I have to remove the rear wheel, drill the frame and insert/ epoxy in standoffs to mount where I prefer (180 degrees behind the lock bracket, in front of rear wheel). I may change my mind, so not ready yet.
AND I LOVE the R1U Panniers (pics coming). Crazy room inside. Abercrombie Fitch quality. I can haul two sixer of 8.0% IPA, a bottle of Chardonnay and all the fixin's for a Rack-of-Lamb Easter Dinner for me and mine, easy - insulated and cold too!!
The Center of Gravity beats groceries on my rack by a mile.
Unfortunately, it's brackets make it +6" higher than my rack (great for hauling a rack battery !!!) which interferes with my Lamborghini class side laser taillights, so I'll have to fabricate a rod for the brackets and attach it to the rack. I assure you it won't be tacky, hose clamped, duct taped, or with a pink ribbon. I have solid aluminum rods that I may use. Half moons dremelled out at appropriate points and a 1" piece of same stock with same cut outs and a bolt through each side. Also, sewing a veclro strap on the bottom to attach to those neat slots on this Streamliner rack's bottom bracket (See Photos), YES !!! Then you can simply undo bottom strap and lift the whole shebang off the rack, sling over your shoulder and in true John Wayne style bring the chilled wine to your damsel !!!
Hard day, burned out hope this helps all. Anything I can add with, feel free to ask direct. Anything you can help me with PLEASE post.
Cavalga como o vento !!!
F n' F
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