Battery tray design
So Loni and I worked last Tues and last night on the Battery Trays. We’re using steel on this design because its easy, and we’re already light on the bike. Its easier for testing/tacking the frame together. We may go back and redo it, but I’m fairly happy with this design.
We need three levels of batteries. 2 batteries in the lowest, 4 in the middle, and 6 on the highest. We got the center of gravity very low. The motor and battery weight is all below the seat/gas tank. For the middle tray we got the absolute maximum size measurements we could for the battery orientation (10″ wide, 11″ long) and cut the trays out of 1/8″ angle iron. We can fit 4 batteries in the middle tray, and will allow access to the 2-battery tray when we fabricate. The upper tray was designed to fit 5 batteries, but in changing the orientation, we discovered that we can fit the remaining 6 batteries in it with room to spare. The batteries and trays all fit inside the frame and allow for the fairings to be installed with no issues. Some tweaking will be involved, but we’re both very happy with the design of the trays.
The upper and middle trays are finished and are tack welded together. They’re clamped onto another piece of angle iron that will serve as the main mounting point. There will also be a front and rear mounting point, as well as a bottom mounting point that incorporates the center stand mount. Next time we go in, we’ll fabricate the lower mount and weld it together with the middle mount and clamp it in the bike and install the fairings. Then we’ll locate the upper tray and tack weld everything together and drill holes for mounting it to the frame (using the original engine mounting holes. So far, the frame has not been drilled or modified.
Here are some pictures:
We should be able to get the mount finished and in place next week. We’ll fill it up with batteries, crimp the connectors, and HOPEFULLY have a ride around the block with the Synkromotive 400A controller we built. No PDA for now, no balancing for now, but it should be running within 2 weeks and at least functional.
Still need to rebuild the rear brake, it won’t return and kind of drags.
httpv://youtube.com/watch?v=D27TJUc1fK8
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Conversion | Travis | 
May 16, 2008 10:25 am
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