Coasterbrake hub builds

[BartRidesEternal]

For that style of intricate pattern, I'd suggest that frisket paper is superior to common masking tape. Find it in art supply stores. It's likely to eliminate any pesky bleed-through and deliver crisp edges.

Thank you for that tip, I will search for that in our local paint shop.

a shaft drive bicycle is on my bucket list.

BRIKbikes, Beixo, and Biomega are brands that work with a shaft.
There are several cheap mountainbikes for sale second hand with these shaft drives:

Nexus 3 hub.

These could be very cool klunkers!



My 'BRIK' front sprocket came in and at first glance I thought they are not compatible.
But when I pushed them together and found the right angle (like a chainstay that goes outwards to the rear) it fits perfectly!

Now I gotta find the standard for the splines so I can machine a shaft. After designing the whole BB offcourse.

19mm outside diameter of the splines.

About 17.3mm inside diameter of splines.

25mm bearing.

Number of teeth.




Excuse me if this is a little offtopic, but its just so cool and not a full on project just yet to make a new topic about it.

 

[BartRidesEternal]

So I calculated the gear ratio.

25 teeth / 11 teeth = 2,27.
Then you have the shaft rotating 2,27 times faster than the BB shaft or cranks.
22 teeth / 26 teeth - 0,84.

This is a total of 2,27x0,84 = 1,9068.

To get an idea how that rides, I used my BO18 bike as a reference:
26x3.0" wheels and tires.
44 teeth front chainring and a 20 teeth rear sprocket.

44t / 20t = 2,2.

If I apply the "shaft drive" gear ratio to the example bike's front chainring:

44t / 1,9068 = 23,07.

So this shaft drive will ride similar to a:
26x3.0" wheel/tire'd bicycle with a 44t - 23t chain drive.

That is not bad, although, taking into consideration that the angle is fixed and that FAT tires do not fit on a BRIK bike, I would probably assemble 28 inch wheels with semi-fatty tires. (AFAP: As Fat As Possible)

 

[BartRidesEternal]

Hi guys,

I have a question:

An old Bendix hub (1946 - 1963) with a steel shell and bronze schoes.
Does it need any lubrication between the brake shoes and shell?
Since my hub was sticking and screaming when braking.
I use the same grease for every hub, works perfectly fine. But these shoes are made of brass instead of steel.

Pictures:

Point 8: Squealing...

The manual says: Light coating of good quality automobile grease.

 

[BartRidesEternal]

I rebuilt the hub. Grease for the bearings and oil for the brake shoes (oil doesn't stick).
It brakes fine. Adjusted well. I don't like to kill a pig everytime I brake

 

[twojs.bike]

I use high temp grease on the brake shoes. But I am certainly not an expert. Probably learned that on YouTube.

 

[BartRidesEternal]

I'm all over the place with my projects again
I felt inspired and started concept modelling a heatsink, flanges and arm for a Shimano CB-E110 hub. Almost all aluminum.

Not finished yet and needs a little reflection in regards to machineability versus clamping, but happy how these high flange modifications look.

Picture above: Assembled. No brake arm and screws are missing.

Picture above: Exploded view.

Picture above: Steel anchor plate with a 44mm pcd. An aluminum brake arm can be mounted there. I'm not confident an aluminum brake arm directly on the toothed CB-E110 anchor is strong enough.

Features:
-Screwed high flanges with 36 or less holes. Reason for screwing (instead of removing the original flanges and pressing the new ones on there) is ease of assembly and less chances of mistakes.
-Heatsink, two pieces. Milled and clamped on the hub with the fins + screws and threaded bushes.
-Ability to change spokes when assembled.

I could make the Heatsink with the fins since its already a piece of aluminum...

I'm playing with the idea of anodising the aluminum parts (blue, purple or red) and selling a few sets like Mone cycles.

 

[BartRidesEternal]

Day 2, changed a few things.
I will build a prototype hub first, so I'm keeping it practical, affordable and fun.

What changed?

• Central aluminum (blue model) heatsink changed to a stock available material. Unfortunately less heatsinky, but still aluminum which I can anodize.
• Cut material from the steel anchor plate. (Dark blue in the model now).
• Aluminum coasterbrake arm, first concept done!
• Hub flanges outer diameter is now 90mm. Pretty large. I might change that to a smaller size.
• Cooling fins attachments now closer to the shell.

With the left hub flange hidden.

Left view.

Anchor plate made visible with red lines.

Section view with cooling fins and attachment visible.

Pretty large flanges. I might change that a little since you can attach the cooling fins after lacing.




Feel free to comment or criticize

 

[BartRidesEternal]

Almost ready to order some materials! Updates:

• I made the flanges a bit smaller and made a few 'aesthetical' concepts. Personally I like concept 2.
• Central fins are larger now, more cooling.

I am aware this is not a full-on efficient, streamlined cooling design, but more a way of having fun and adding weight (I like to torture myself on the trails)
The main focus on this build is a cheap first concept and improve the design after use.
Lets break that down:

1. Screws to clamp the fins are stock.
2. Threaded bushes that are used for clamping are stock.
3. All parts can be lasercut or cut with a waterjet. The spoke flanges need extra machining afterwards.
4. Aluminium parts can be anodised for aesthetic purposes.

Flange concept 1.

Flange concept 2.


This is how its done:

Updated total 3D view.

 

[BartRidesEternal]

Update: (sorry, I do not give anyone time to react )
Flange concept2 is the one I am going for in the prototype.
I ordered base materials and asked for pricing regarding the lasercut parts.

In total four prototypes for four CBE-110 hubs. I know a few people that might be interested.
Plus there is a vintage mountainbike fair the 15th of December, I hope to finish and showcase a few hubs by then

I will try and get parts to be anodized in various colours.

 

[BartRidesEternal]

I ordered four prototypes!

Thinking about assembling the fins; It might be a bit of a pain in the hiney but worth it eventually.

Here some neat pictures:

Edit: This is nuts:

 

[BartRidesEternal]

Wow!! Parts came in fast! I haven't even payed for the lasercut parts yet.

Fins loosely balancing on there. Will be closer together when finished later.

 

[BartRidesEternal]

I started inventory today 'what do I need to machine' before its a plug and play set?

I disassembled a Shimano coasterbrake hub and cleaned it. I instantly tried the flanges on and it fits very tight, but you can press them on by hand.

To do:
A) Countersunk holes for the spoke heads.
B) Remove a little bit of the flanges for dust cap clearance.
C) Machine the aluminum clamping bushes.
D) Assemble with a heat sink 'transfer' paste.

I'll build two hubs and I will finish and anodize the remaining two.

 

[ifitsfreeitsforme]

this is interesting to follow along to. Are the heat sinks aluminum?

 

[BartRidesEternal]

this is interesting to follow along to. Are the heat sinks aluminum?

Yes! Aluminum, it can transfer/ lose heat better than steel.

I have done very simple calculations. But I could do a test with an actual heat signature camera. That would be awesome.

I was also thinking about the arm and anchor. The anchor is now made from steel due to strength and assembled with an aluminum arm. But I could make that out of titanium... light, strong.... don't know about heat dissipation.

Anchors now have thread and are painted.

Holes countersunk.

 

[BartRidesEternal]

I milled the inner holes and removed 2mm for the original dustcaps.

Anchor assembled.

There is enough clearance.

It is even harder now for dirt to get in.

I'll build two hubs to showcase at the SWAPmeet in December.
The other two will get the colour anodized treatment.

Then testing!

 

[ifitsfreeitsforme]

did you or are you going to modify any of the guts for max cooling/lubrication? I recall seeing videos about chamfering certain internal parts, and maybe other mods to improve brake pad cooling and keeping grease where it's supposed to be.

 

[BartRidesEternal]

did you or are you going to modify any of the guts for max cooling/lubrication? I recall seeing videos about chamfering certain internal parts, and maybe other mods to improve brake pad cooling and keeping grease where it's supposed to be.

Great question! I did nothing in regards to internals. Only a high end grease.
I saw descriptions from other modders removing the ball bearing cage and indeed chamfering the brake pads. I wonder what part? I haven't observed that part enough yet

 

[MattiThundrrr]

Great question! I did nothing in regards to internals. Only a high end grease.

That should probably be enough for those Dutch hills.

 

[BartRidesEternal]

I am not building a heatsink since the Netherlands is flat!

Oh sigh...... I thought lets get back to it myself before someone else does


But check this out:

Hmm. Installation is not as easy as I thought. Harder when spokes are there. Have to test that again when a wheels is laced.

No1 is done.

Original hub.

400 grams of cool.

No2 combined with the shaft drive for next sunday.

Sunday is a retro swapmeet:
I have a modest stand there with some stuff to show, sell and tell.
Looking forward to it!

 

[MattiThundrrr]

Sunday is a retro swapmeet:

Pictures are a must, or you're in trouble