Update Jan 2018. After repeated attempts to get a belt driven ebike working and having at least 2 belts break, I have come to the conclusion that it's simply not worth it to go belt driven. Just get a hub motor and be done with all the headache and time wasted.
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This is a parametric version of the pulley used in StatonFrames pulley. Now you can choose the number of spokes and locations of the zip ties and stuff for you specific bike.
The conversion is VERY finicky. I'd recommend printing out a profile test of the pulley before committing the plastic for a full pulley and check for fit. Be prepared to spent lots of time on this project.
I also redid the motor mount. I am actually not happy with it currently but I will post it and it might be okay for someone else. The plastic motor mount flexes too much and I switched to a metal motor mount with plastic clamps to mount to the frame tube. Will post pictures soon.
The motor mount was made in autodesk inventor. You'll need autodesk inventor if you want to change some parameters in that.
There's also a motor fan if you want to use that. It should improve motor cooling.
- 4 x 2 1/4" 5/16 bolts OR M8 metric equivalent
- 1 x 5/16 bolt for bearings (length depends on # of bearings used for idler)
- 2-3 x 608 bearings
- 5/16 washers and nuts
- M4 bolts for motor (should come with motor)
You'll want the motor mount at least 50% for strength. The pulley I printed at 25% and it seems to be okay for now ( after a few trial runs). Supports not required.