Electric Motorcycle conversion

[Daox]

I'd say definitely come in work clothes. Getting your hands dirty is a lot more fun than standing around.

[kingofrandom92]

sounds like a plan

[bennelson]

I'll be at the Makerspace pretty much all day Sunday.

I wear the same outfit every time. I know how dirty I get when I am working on projects.....

[bennelson]

Got some work done on the cycle today.

My brother is back in town, so he came over to give me a hand. I don't have any experience with auto body, and he does, so he started some work on the cycle gas tank, filling in the bad spots with Bondo.



A coat each of two different colors of primer would help show the low spots with a little sanding.



The heat wave here is past, instead it was cold and rainy, so we were using halogen work lights to speed up the paint drying.



I also got the battery rack primed and painted, and then reinstalled in the cycle.



We also sketched out where the fuse, ammeter, key, shut-off, and other misc bits would go.



Here's where they will go on the cycle.


I also got the tail/turn lights installed!


Rear brake was adjusted and electronic throttle was installed too.

I can't wait to get the tank painted. That's one of those moments that really starts to make it feel like you're getting somewhere.

[kingofrandom92]

Ben- glad I could help out today. it was a blast and the Milwaukee Makerspace is awesome. put up a link on facebook about the bike and makerspace- maybe it will get a few more hits in the next few hours.

thanks for the great day of DIY on motorcycle conversions.

[bennelson]

Great having you there!

I actually got stuff done today!

Chain went on. The fuse/ammeter/shut-off/contactor sub-panel got bolted up. Wired all the batteries up. Redid the front brake.

Jacked it up, spun the back tire, did a very basic test ride.

Still need to add a third point of contact to the motor mount and tighten a bunch of things down.

The gas tank was looking really good with its four coats of yellow Rustoleum.

Several people said that I should put some clear coat on it. I did, and the paint had a bad reaction to it! Looks like it's back to sanding!

Just wish I had gotten more photos and video. It's had to both DO something and take photos, make videos, etc....

Thanks again Stephan!

[Christ]

Just wish I had gotten more photos and video. It's had to both DO something and take photos, make videos, etc....

Very much the truth here...

[bennelson]

Here's a presentation on how to do this kind of stuff:

http://www.youtube.com/watch?v=ikOqnkIJrLg

[bennelson]

More video.
Got the cycle running under its own power. This is just a light rolling test to make sure everything is working right. Still lots of things to tighten down and a switch or two to install.

http://www.youtube.com/watch?v=n5JeVje-FT8

[Wytknyt]

Nice video..... love the Tron part. When i first heard about electric motorcycles that is what i thought of too. Now we just have to figure out how to handle the 90 degree insta-turns.