THanks for the note. I am looking into it now. They are drilled out too but I hope there are pins of some kind to support the gears together further out on the gear close to the teeth.
This project was a test on the HD motor, not the bike. I fully expected to have to upgrade components, which I have, to test the BBSHD more than anything. The programming is totally different than the old BBS02. I don't know why they changed it so much. Even the new 02 controllers had program change on the firmware side. I have spent well over 20 hrs programming and countless hours researching and email support with MFG's and distributors and finally just turned off the pedal assist completely. Have 10% power on start up and after trying the 3 types that are available with these kits, I upgraded the throttle to a real one ($90) so it is more progressive and predictable. I have 2 controllers for it now, one stock and the other has the PAS resistor mod. This is not my first rodeo.
I will share my program with anyone if they want to try it.
Cheap walmart bikes are cheap for many reasons. To start it is the components. Get rid of all that matters and upgrade which I have done here. Frames are all made by the same few companies. Cheap frames are made from mild surprise tubing but there is little wrong with this outside of weight. They way over build the frames because of the production time they are willing to spend on those frames. The stays are 7/8" to 1" and probably .049 or heavier wall. I do not suspect frame flex. Most issues with cheap frames are the brazeons on every level. THey have thickened up the tubing so few failures if any are happening at the dropouts especially. I see NO frame repairs or even get calls these days on cheap bikes. Way more on expensive light weight bikes. I used to repair tons of mild surprise frames and now none are being brought in. Maybe they are just disposable and not being repaired anymore?
A little note: I was hired by the Derby Corp. as a production consultant to go to the Raleigh factories and evaluate production and to cut costs even more. Number crunching A-Holes get in the way of quality products and sound production techniques. They were happy with a 2% failure rate back in the day, so off I went.
Little things like DO and hanger alignment are suspect but easily checked and fixed. I don't suspect the stamped steel vertical drop outs (which are insanely thick) but more so the QR axle. The hub spacing is a whopping 192mm so chainline is much better than most.. Together with the width and 10mm QR axle in this hub, the problem maybe there. I feel that a 10mm axle this length is the issue although it is staying in adjustment fine. I should of got a bolt on axle. The derailleur is off of my Moots so nothing cheap there, XTR. Shifter is cheap but works fine.