V2.0: And it begins…. again…

(click on image for more pictures)

So, its been a REALLY long time since I’ve posted pictures of my project…. It’s been a busy year. Worked with the Motoczysz team for a while, started consulting, imported 25k of batteries and then did some consulting for a parts distributor.

Now I finally have most of the parts I need to finish the bike. I don’t have the Synkromotive controller yet. I don’t have a BMS either, but I’m working with Elithion on some BMS stuff for us moto guys, and I’ll be testing his prototype. Right now I’m planning on the Lithiumate system with Cylindrical cell boards.

So what changed on my bike? Well, almost everything is changing. I decided to make the leap from Lead to Lithium before even installing the Panasonic SLA’s. It wasn’t enough of a gain, and would be much better long term to go Lifepo4. The fairings are no longer the stock plastic, they’re all fiberglass…. Including the gas tank.

So whats going in the bike?:

• 192qty 10Ah 38120S Headway cells in 32s6p for 102V 60Ah
• Fiberglass one-piece tail fairing, Solo seat cowl, front fender, race upper fairing, lower side fairings, inner fairings and gas tank.
• taller windscreen to help cut back on aero drag a little
• K99-4003 72V 6.7″ motor from Advanced DC
• delta-q 1000W 96V charger setup for 32 cells (116.8V cutoff)
• Vicor 100Vin 12Vout 200W DC-DC converter (works down to like 80Vinput)
• Inertia switch in case of a wreck
• LSL MIG Dual headlights
• Sprocket Specialists 60tooth anodized rear sprocket
• Bar mounts so I can use a sportbike/superbike style handlebar

Stuff I don’t have yet:

• Controller (Want to use Synkromotive, might have to get a Zilla)
• BMS (I’ll likely use a full Elithion Lithiumate BMS)

Stuff I need to do:

• Fabricate new motor mount (the old one could be improved and simplified)
• Fabricate a battery box for the Headway cells
• Fabricate headlight mount and cut holes into upper fairing
• fabricate charger mount
• mount controller/contactor/DC-DC etc inside gas tank
• rebuild front forks (they’re leaking)
• replace wheel bearings (since its easier now than later)
• Get fairings sanded and painted
• get wheels/subframe/gauge mounts/panel mounts powdercoated (this could wait until after bike is done)
• Talk with Elithion about their BMS and see if I can still integrate an LCD

So thats about it for now, gotta check in on the controller and BMS. Talked to a welder the other day, and they said they’ll help me with that side of things so I just need to get some shop time to map out the battery assembly.

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1 Comment

• By Todd, October 7, 2009 @ 11:34 pm

  Hi Travis,
  Where did you get the inertial switch? Any strange mounting positions? Really good idea, hook me up
  -Todd

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