Dropout Mod for 1500w

500w_Of_Power

500w_Of_Power

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Hi, I'm building a 1500w e-bike on 48v and the dropouts are aluminum, they just barely go over the axle. I was thinking of machining some 1/4in 304 stainless steel from SendCutSend to make extended dropouts, then adding a torque arm. I would bolt them on, and use JB Weld Steel epoxy for added strength. You can see my cardboard and paper mock-ups. Is this a good idea, or should I look for a steel frame? This frame is a DimondBack Overdrive 27.5 large frame: https://www.costco.com/diamondback-overdrive-27.5"-bike.product.100744715.html
 

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What you are describing is excellent if you want to make your life insurance policy a good investment for your next of kin.

STEEL.
 
From what I can see the dropout depth is the average size seen on most bikes. Can you show a picture of the hub axle to be used placed in the dropout? I would not recommend the modification shown; the dropout does not normally need to be so deep.
 
Your main concern is trying to prevent the axle from spinning in the dropouts. Designing deeper dropouts is not the answer. Your best option is a pinch torque arm on both sides. Don't be tempted to cheap out; buy quality torque arms and be done with it.

V7 Regen Torque Arm 12mm

V7 Torque Arm with Machined Clamping Block for Regen Hub Motors. Fits M12 Axles in both Front and Rear Installations. Must be Installed on Solid Axle (No Cable) for Full Strength.
ebikes.ca ebikes.ca
 
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