Belaero Build Thread, Here we go again! :-)

[todayican]

Ok, its official, the saw has hit the steel, the chassis work has begun :-)

Im building a high mpg reverse trike with an eye on getting the most miles per dollar of overall cost to own (lots of ways to get to that, beleive me!)

My goal is to build something I can post plans to free and help people build a 100mpg plus vehicle (at 70 mph)that can carry 2 people and 6 bags of groceries.

And all for under 5k ICE only and 10k ev with 100 mile range.

The idea is to build the "forward cabin" the entire chassis forward of the rear seats back as a unit and build interchangeable rear sections. (electric and serial hybrids would be able to carry a 18" shorter wheelbase = lighter car

The first drive iteration Ill build will be 72v ev drive system 40 to 60ah of thundersky batteries and a 7hp gas engine turning a generator.

The 2 motors will be an etek-s for the drive motor, its brand new 500a for 3 minutes and 150a continuous . its like a regular eteks big brother :-)
Mars ET-RT Permenant Magnet Motor

Gen will be an etek rt slightly smaller and less expensive:
Mars ET-RT Permenant Magnet Motor

The chassis measurements under "serial hybrid / ev mode will be 78" wheelbase, 116" overall length and 55" across at the outsides of the wheels.

Here are some early build pics and odds and ends:

(the pencil drawing a) is very bad, still looking for some help with 3d modeling) :-) and b) reflects the longer wheelbase gas engine version.

150mpg here we come! :-)

[Frank Lee]

Electrics are usually heavier right?

[todayican]

This first build is only going to have 40 to 60 ah (80 to 130 pounds) of batteries, a little heavier, but not ungodly heavy.

[SVOboy]

Looking forward to more updates

[NeilBlanchard]

It is great to see what you have done -- starting is the hardest part, in my opinion.

As we learned from Allert Jacobs DIY aerodynamic fairings on a Honda 125cc motorbike, and from the X-Prize Knockout Round results -- the weight of a vehicle is less important than the aero drag.

The efficiency of the drivetrain is the most important.
The aerodynamic drag is the next most important.
Weight is third most important.
Vehicle rolling efficiency is the fourth most important.

The reason that weight is less important than aerodynamic drag is that weight gives momentum, so while it takes more to accelerate a heavier car, it then coasts better. You inherently regain some of the energy.

Aerodynamic drag is a total loss. Rolling resistance is a total loss, too, but it is much lower magnitude and linear. Aerodynamic drag is exponential, and so it is orders of magnitude greater.

So, the challenge with your interchangeable parts will be alignment and robust strength and rigidity.

[Toby]

Very cool.

Out of personal curiosity I have to ask these ugly questions:
1) What about crash-worthiness?
2) How will you insure it?
3) Do you have to pass safety/road-worthiness inspections where you live?

[todayican]

Excellent questions Toby!

Crash worthiness: I'm shooting for "Really safe motorcycle". It will be registered and insured as a motorcycle, I will get a "MSO" from one of the chopper builders on eBay (done it before).

It will have a roll bar directly over the forward riders head of rolled 1 1/4 round. and a 1x2" support over the rear riders head forming the rear bulkhead.

The frame rails extend up 16" from the floor so decent side impact protection, not "Volvo caliber" im guessing though.

The forward rider will be essencially surrounded by the front wheels so good side impact coming from the wheels and suspension itself.

The area im not in love with is the very front. The riders feet will extend about 8" past the front of the wheels. Its a consideration to balance. I will use 2x1" top and bottom there and fill the entire nose area with foam forward of the drivers feet ala tri magnum.

No inspection in FL (Im pretty sure, since its technically a motorcycle, inspections would be exempt, or strictly a function of emissions and "do the blinkers work" in other states should someone else want to build one?

[NeilBlanchard]

A safety concept that I learned from Oliver Kuttner of Edison2, is deflection (vs engagement). If you protect the people with a structure that is shaped to deflect away from the object that you are crashing into, then you will go a long way to having a safer vehicle. Look at the Edison2 Very Light Car or Formula 1 cars, etc. for what this looks like.

[todayican]

Excellent advice Niel! Thanks.

[todayican]

sorry, Neil :-)