Oily Posted December 21, 2015 Share Posted December 21, 2015 So, after my failed dual battery install & my planned 500W motor upgrade, it's got me thinking about my shell/housing. Top speed with the 500W motor isn't my ultimate goal - it's being able to beat the train/walk on my current commute, so being able to average 12+ mph is a requirement for nearly an hour ! This got me thinking about batteries - now I can go to 340 ina single unit for not a huge amount of money, but I don't know if it will actually fit in my EUC (14" Chinese Huwei I believe), which then got me thinking about housings.... Does anyone just sell housings ? I've found an airwheel X8 housing on Evilbay for £60, but its a very similar design to my current wheel so I don't know if dual batteries would still work. The other options I guess is to build my own out of fiberglass - has anyone done this ? I'd be tempted to build in an alloy or steel handle across the unit for strength, but to also mean I wouldn't need huge strength in the brag handle ? Thoughts ? Link to comment Share on other sites More sharing options...
esaj Posted December 21, 2015 Share Posted December 21, 2015 9 hours ago, Oily said: So, after my failed dual battery install & my planned 500W motor upgrade, it's got me thinking about my shell/housing. Top speed with the 500W motor isn't my ultimate goal - it's being able to beat the train/walk on my current commute, so being able to average 12+ mph is a requirement for nearly an hour ! This got me thinking about batteries - now I can go to 340 ina single unit for not a huge amount of money, but I don't know if it will actually fit in my EUC (14" Chinese Huwei I believe), which then got me thinking about housings.... Does anyone just sell housings ? I've found an airwheel X8 housing on Evilbay for £60, but its a very similar design to my current wheel so I don't know if dual batteries would still work. The other options I guess is to build my own out of fiberglass - has anyone done this ? I'd be tempted to build in an alloy or steel handle across the unit for strength, but to also mean I wouldn't need huge strength in the brag handle ? Thoughts ? I've built a custom aluminum frame that I plan to try to cover with fiberglass (and later on, carbon fiber + aramid aka kevlar), but the project's been currently on hold due to lack of time and space (need to keep the car in the garage as it's getting colder ). http://forum.electricunicycle.org/topic/1257-custom-wheel-frameshell/ Link to comment Share on other sites More sharing options...
Oily Posted December 21, 2015 Author Share Posted December 21, 2015 That's some serious construction work going on there ! I was thinking more along the lines of take a mold from the existing case, then using something like modelling clay, literally sculpt a bigger version of what I already have, I can then use the clay model to make a new case (or if really going to town, another mold so I can create another one when I break the first !). Link to comment Share on other sites More sharing options...
esaj Posted December 21, 2015 Share Posted December 21, 2015 12 minutes ago, Oily said: That's some serious construction work going on there ! I was thinking more along the lines of take a mold from the existing case, then using something like modelling clay, literally sculpt a bigger version of what I already have, I can then use the clay model to make a new case (or if really going to town, another mold so I can create another one when I break the first !). Yeah, making a negative mold (you probably want a smooth outside) of the original shell shouldn't be too hard, although you'll probably want to do a bit of research on releasing agents/waxes and such involved when using the mold (so that you actually get the final piece out of the mold) I was planning on trying with fiber glass first (because it's cheaper), and if it works, then make the "final" shells from carbon fiber & carbon/aramid-fiber (carbon fiber on the outside, mixed fiber inside). If I remember correctly, carbon fiber is weakened by UV-radiation, so might need some anti-UV top-coating also. My shell will be simpler (not much curvature/convex/concave shapes), so likely it'll be easier, but still need some kind of mold. But probably will have to wait until spring / next summer, apparently the resin fumes aren't that healthy (well ventilated area needed) and the stuff needs at least room temperature to harden properly, preferably heat treating in 50-80C after initial hardening to get the final hardness (that's what the sauna's for, right? ). Link to comment Share on other sites More sharing options...
Oily Posted December 22, 2015 Author Share Posted December 22, 2015 Well I've been looking at carbon & kevlar kits, and I think this looks like a good bet - getting the skin to work may be interesting as you'll have an inner & outer which will need bonding, but thats not too bad - what going to take a bit more thinking is how to create the screw fixing points/posts in the carbon. I'm thinking bonding aluminuim tubes to the carbon & then using nice stainless nuts & bolts to hold the 2 halves together (althoguh if I'm going this route, I suppose I could create a lip on 1 side of the housing & not have to worry about the tubes..... Watch this space..... (although current Saab engine rebuild is taking a lot more time that it should & my wife is car-less, so this is taking priority !) Link to comment Share on other sites More sharing options...
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