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Old 06-16-2009, 04:09 PM   #111 (permalink)
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Just some intermediate tedium today. Mounted the controller under the seat. And made the under-tank bucket for holding all of the electrical components.

Have to cut out a hole for mounting the 5V DC-DC converter, and make a plate to hold the 12V DC-DC converter.

Then I get to start running wires.
Quote:
Originally Posted by wolfraven View Post
Is that 2 motors in there?
Just the one with a two-stage chain reduction and freewheel.

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Old 06-16-2009, 07:42 PM   #112 (permalink)
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Eh, there is a 2 motor setup in an electric dirtbike (I forgot where)...it's sweet. I'm saving for a similar project, and if it pans out, I'll be going with ideas from both that project, and yours, and maybe a few other places...but, it could take a while, lol!
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Old 06-19-2009, 07:29 PM   #113 (permalink)
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Well, I lost Wednesday and Thursday due to some bad weather messing with my arthritis. I only had half a day today to work on a few tedious things.

I made a plate to hold the magnet for the speedometer sensor. Then mounted the sensor on the rear fork.

I finished most of the wiring. But I forgot to connect the 12V DC-DC converter ON/OFF to Vin- so it fried once it received input voltage.

I jacked the rear wheel off of the ground and hooked up a power supply in place of the DC converter. I then ran a speed test of the rear wheel.

First test the speedometer was reporting 41.5MPH at full throttle.

I'll have to do more testing on Monday after I can confirm that the speedometer has an accurate wheel circumference inputted. And once I get a replacement 12v DC-DC converter and I can do some ride testing.

The freewheel mechanism and chain transmission works great. I do need to add a tensioner to the rear wheel chain though.

More developments as they happen and I'll explain the electrical setup better once I have it finished.

Quote:
Originally Posted by wolfraven View Post
Eh, there is a 2 motor setup in an electric dirtbike (I forgot where)...it's sweet.
There's this one

Performance Electric Conversion - CRF250R to CRF2eR
And this one

Endless-sphere.com • View topic - "Suzuk-E" RM125 Conversion

Last edited by captainslug; 06-19-2009 at 07:37 PM..
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Old 06-19-2009, 09:09 PM   #114 (permalink)
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Impressive schematic. What software did you use? And WOW on the bike
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Old 06-19-2009, 09:22 PM   #115 (permalink)
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Quote:
Originally Posted by JayC View Post
Impressive schematic. What software did you use?
I started it in the Alibre Xpress (Free CAD software I've used to design all of the parts I made for this) but that was getting tedious.

I ended up just making a bunch of changes to it in Paint Shop Pro 5.
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Old 06-20-2009, 10:46 AM   #116 (permalink)
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Yeah, I saw the first one...that's what I thought you were going for...I didn't remember the reduction part...I think if/when I get the money saved up for my own electric motorcycle, I'll be going with maybe half of how you're doing things (I love the custom stuff...it's amazing!) and the dual-motor setup from the CRF2eR, with some bigger motors...but I'm still looking out for a reasonable frame...I found one, actually...and it would work/fit perfect, except there's a perfectly awesome 750 Honda engine in it...so I'm mostly going to just grab it, and ride it until there's no more hope for it...looking for another frame similar lol! I've only seen 1 electric motorcycle that wasn't at least partially faired up with plastics...I like my big cruisers...that would be my style of E-motorcycle, any day...let them SEE the motor(s) and gears, and even the battery box! Still, yours looks awesome
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Old 06-22-2009, 03:47 PM   #117 (permalink)
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I'm having a bad day: Turn signal relay doesn't work, 12volt horn doesn't work, and I screwed up the first turn signal assembly
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Old 06-22-2009, 09:15 PM   #118 (permalink)
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Quote:
Originally Posted by captainslug View Post
I'm having a bad day
That's ok.

I have set my car on fire, cut my brake lines with a plasma cutter, zapped with 72V, zapped with 144v, short-circuited 144V, and gotten a fossil-fuel free speeding ticket!

Just think of it as a fun learning experience!

Seriously though, I know it gets frustrating when things don't go right!

The project really does look great.
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Old 06-26-2009, 12:22 PM   #119 (permalink)
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Remade the left side motor-mount plate out of aluminum.

Front turn signals and headlight are mostly done.


Still working on the rear chain tensioner and general wiring.
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Old 07-06-2009, 04:55 PM   #120 (permalink)
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Had to rewire some of the electrical system on Friday in order to replace the two DC converters with a single triple output model. This was done to reduce the current load on the ignition keyswitch, and reduce cable clutter.

Voltmeter installed.

Charger installed in the tank shell. I extended its indicator lights so that they backlight the plug receptacle in the tank bung.

Currently waiting on some small parts to arrive in the mail.

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