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Discussion Starter #1 (Edited)
Broken Spokes seem to plague the EZip bikes.

Further investigation was done!

Turns out, there are multiple reasons for these failures!

1. Torque is mono-directional, but typically, this is not accounted for.
The "torqued" spokes should have their elbows turned outward!



All EZips, I've had, have one side turned inward, one outward. (4 EZips, 1 IZip)

2. Hub spoke flange is too thin, spokes are not supported, so there is excessive stress on he spoke "elbow" causing early failure!

Solutions?

1. Re-directionalize spokes. (Partial solution)



2. Use better hub. I lucked into a few of these, present source unknown.





3. 12 gauge spokes with "proper directionalty".
The EZip uses 14ga 258mm & 260mm spokes, I was able to find 260 & 261mm 12ga, closest match, extra length was on purpose ...
This still doesn't address the issue of the spoke flange being too thin, so ... washers!
#4 SAE washers work nicely, and look impressive!




Nice and SOLID!





Oh! Why the "longer" spokes.
Well, with the spokes "solidified" and capable of great strength, the weak point, is now the wheel, being a cheap alloy extrusion.
Might even pull the nipples, through the wheel.

So ... washers!
#10 SAE "stamped" washers have a nice concave side, that works nicely with 12ga nipples.
Aluminum alloy wheels don't particularly like steel, even zinc coated steel washers, against them, so I ran 2 wraps of duct tape between.


 

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Discussion Starter #2
Presently, I am testing 3 prototypes.

1. EZip Stepthrough, with oem spokes re-directionalized.

2. New alloy hub with new "WheelSmith" stainless spokes, properly laced to support torque. (Hub has smaller spoke flange diameter, used 262 & 264mm spokes - eZip oem are 258 & 260mm.)

3. "EnArmored"
EZip hub re-laced with 12ga spokes and #4 SAE washers.
Probably overkill, should have gone with a better wheel!
Gotta put it on a heavy hauler

I would recommend relacing the oem wheel, for proper torque support, but also, adding #4 washers to all spokes.
 

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Discussion Starter #3
Re-Spoked!

Presently, I am testing 3 prototype rebuilds.

1. EZip Stepthrough, with oem spokes re-directionalized.
Even though these spokes were previously abused!
1200+ miles and no problems! - Update

2. New alloy hub with new "WheelSmith" stainless spokes, properly laced to support torque. (Hub has smaller spoke flange diameter, used 262 & 264mm spokes - eZip oem are 258 & 260mm.)
I did re-tension spokes after initial break in, new hub, spokes and nipples in old wheel.
1600+ miles and no problems! - Update

3. "EnArmored"
EZip hub re-laced with 12ga spokes and #4 SAE washers.
Probably overkill, should have gone with a better wheel!
Gotta put it on a heavy hauler
Sorry! My "simpler" "solutions" seem to have rendered this heavy duty re-build ... unnecessary?
I did purchase a 3/16 Southpaw freewheel, in case I wish to rig a more powerful motor.
Still, not placed in service ... yet. - Update
 

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Discussion Starter #4
14g EZip "Relace"

Presently, I am testing 3 prototype rebuilds.

1. EZip Stepthrough, with oem spokes re-directionalized.
Even though these spokes were previously abused!
1200+ miles and no problems! - Update
Near the 2000 mile point, one of the abused oem spokes broke ... not surprised.

Decided to use the last of my 14g steel spokes, for a properly directionalized, "washered" install.

Purpose -
1. To test the effectiveness of spokes laced to best support the stress of an externally motored wheel.
2. To test a method of better supporting elbow stress.

Parts:
18 - 258mm UCP (universal chrome plated) spokes
18 - 260mm UCP spokes
36 - #4 stainless steel washers
36 - M4 stainless steel washers

Tools -
Scotch tape ... ?
"Proper" spoke wrenches.
Cordless drill with "slot" bit.

When previously working with 12g spokes, I found it advantageous to pre-position the spokes.
Scotch tape worked nicely


#4 washers pulled the spoke "elbows" nicely close to the hub flange.


M4 stainless washers (accidentally purchased) gave secure corrosion free seating to the spoke nipples.


Completed relace.


P.S. As a test item, I applied a synthetic chain lube to the threads of the steel spokes.
Anti-rust?
 

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Discussion Starter #7 (Edited)
Presently, I am testing 3 prototype rebuilds.

1. EZip Stepthrough, with oem spokes re-directionalized.
Even though these spokes were previously abused!
2000+ miles and no problems! - Update
"Properly" relaced with cheap, but new, 14g spokes.
2000+ more miles with no problems.


2. New alloy hub with new "WheelSmith" stainless spokes, properly laced to support torque. (Hub has smaller spoke flange diameter, used 262 & 264mm spokes - eZip oem are 258 & 260mm.)
I did re-tension spokes after initial break in, new hub, spokes and nipples in old wheel.
3500+ miles and no problems! - Update

3. "EnArmored"
EZip hub re-laced with 12ga spokes and #4 SAE washers.
Probably overkill, should have gone with a better wheel!
Gotta put it on a heavy hauler
Sorry! My "simpler" "solutions" seem to have rendered this heavy duty re-build ... unnecessary?
I did purchase a 3/16 Southpaw freewheel, in case I wish to rig a more powerful motor.
Still, not placed in service ... yet. - Update
 
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