Another RG250 with Colossus Motor

[SplinterOz]

Ok so I can't measure for cr@p... but with a little work I can use this box.

BMS fitted

BMS Mounted - 00 by Splinter, on Flickr

12 volt and control plugs

BMS Mounted - 01 by Splinter, on Flickr

Bad Measurement on my part (fixable)

BMS Mounted - 03 by Splinter, on Flickr

Fan if needed

BMS Mounted - 05 by Splinter, on Flickr

Plugged In

BMS Mounted - 06 by Splinter, on Flickr

Lights On

BMS Mounted - 07 by Splinter, on Flickr

If I could get a week off work I would love to get this done and dusted.

[jonescg]

Love the hole cutting Tony Looks like something I'd do, except there wouldn't be a straight line anywhere.

Must be so frustrating for you to be so close, yet have next to no time to finish it

[SplinterOz]

Must be so frustrating for you to be so close, yet have next to no time to finish it

Indeed it is... as Arlo1 would say... Hurry Up!

[Arlo1]

Must be so frustrating for you to be so close, yet have next to no time to finish it

Indeed it is... as Arlo1 would say... Hurry Up!

lol I was thinking that before I even clicked on your thread

[SplinterOz]

Today Luke dropped over with a few of the panels that have been painted. The rest will come next week as the guy is having problems with the fiber-glass panels and bubbling. (sorry for the photo quality I was loosing light fast)


Some Panels fitted by Splinter, on Flickr


Some panels fitted by Splinter, on Flickr


New tank by Splinter, on Flickr


With nose cone by Splinter, on Flickr
The nose cone is not yet done, this is the older one that is a little broken.

So what to you call a tank that does not hold fluid anymore?

[jonescg]

Looking good Tony! The tank cover looks very professional! I should get around to designing a better cover for Voltron one day.

Does it turn a wheel yet?

[SplinterOz]

Does it turn a wheel yet?

Not with this battery pack but prior to the pack construction yep. Next two weeks is to build the controller and contactor mounts. Then ride again.

[SplinterOz]

Ok so a few more panels later and a wet, dank, dark day....


IMG_20120603_162900 by Splinter, on Flickr


IMG_20120603_162600 by Splinter, on Flickr

[SplinterOz]

Ok due to the fact that work is taking over my life, winter is here and in my tin shed it is normally -2 in the evenings I haven't done much.

But what I have done is looking good.


Panels fitted - Semi Naked Style by Splinter, on Flickr


Panels fitted by Splinter, on Flickr


Panels fitted by Splinter, on Flickr

[jonescg]

Looking good Tony! Did you get all of the panels re-made in fibreglass? Or just tidy up the ones it came with?

Sorry to hear about work taking up valuable e-moto time. I have the opposite problem, except my e-moto time isn't particularly valuable

Why is the motor still out?

[SplinterOz]

Looking good Tony! Did you get all of the panels re-made in fibreglass? Or just tidy up the ones it came with?

Sorry to hear about work taking up valuable e-moto time. I have the opposite problem, except my e-moto time isn't particularly valuable

Why is the motor still out?

Ducktail and side panels are original. Nosecone and middle panels are fibreglass, lower ones are currently original (not on bike)

Motor is still out as I am yet to get the mounting plate for the controller, contactor etc. Once I have that on I will be able to get everything bolted up in it's final location.

[SplinterOz]

Yes that is my bike, yes it goes, yes the Colossus is running fine.

Not as much getup as I would like... will be looking into that.

[jonescg]

I'm guessing the jacket is for the climate, not for safety reasons

Nice work Tony! I'm impressed the little colossus does the job, but I can understand the need for more power

Should be good for some on-board footage now

[Lebowski]

what kind of controller are you using ? Voltage, current, phase amps ?

[SplinterOz]

I'm guessing the jacket is for the climate, not for safety reasons

Nice work Tony! I'm impressed the little colossus does the job, but I can understand the need for more power

Should be good for some on-board footage now

Yes a max of 9 here today. To be honest that is one of the reasons not much has been done... my shed is cold.

The little colossus is not working hard just the controller not pushing it yet.

[SplinterOz]

what kind of controller are you using ? Voltage, current, phase amps ?

Kelly controller, 72 volts, 500amps max for the controller. Currently I am not pully more than 100amps from the battery.

[Arlo1]

Congrats man can't wait to see you up the power to ~ 1000 amps!

[SplinterOz]

Congrats man can't wait to see you up the power to ~ 1000 amps!

Same here. I am away this weekend with the TTXGP over here, should be back at it next week.

[Ratking]

Oh man I want to see this motor being pushed a bit. Fantastic work so far. I hope you get what you want out of the build.
I'm interested to hear about your opinion about having a compact gearbox. Seems to me that we could get a much greater range of acceleration and speed.

[Astropower]

Nice job you done here,

Why you dont add transmission? -for better acceleration and the ability to drive uphill, and most importantly, it saving a lot of battery energy.

[SplinterOz]

Astropower... main reason for no transmission is no room in a little 250 frame.

[Arlo1]

As a rule the same performance benefit you can get from a transmission can be had by just using a bigger motor. The end result would weigh the same and give you about the same increase of power. BUT a bigger motor has fewer moving parts to brake and is simpler to install and maintain!

Colossus can run 20-30HP continuous with a good cooling system and their is signs showing it should take 50kw (67HP) for ~10 sec! Because of its efficiency maybe more but it will also depend on batteries and the voltage Splinter uses. Right now Splinter is running around 10hp or less. So once he ups the power he will have a fairly quick bike and hills should not be a problem!

[Astropower]

You can read this article and see the test results of Gear and NON-Gear with benefits when installed gearbox.
http://www.fallbrooktech.com/sites/default/files/videos/LEV_CVT_Whitepaperrev10.pdf
This is Automatic Gear system.

I have this system on my Scooter, (see the rear wheel, that is not Hub motor)

2012-08-15_19-15-58_478.jpg (159.99 KiB) Viewed 868 times

viewtopic.php?f=35&t=38385

i can tell you, that i got huge differernt when i turn off the gear and turn on the gear. and it save me space because it is hub gear wheel.
i can drive any place and any hill, with 180KG Load of two people without problem. with 1.2KW motor only (1.9KW Peak maximum i get in my scooter screen).

[SplinterOz]

ok so it has been weeks and weeks. Most of this time has been at work (upwards of 70 hours most weeks) or sick, laid out all last week.
However I have managed to layout all the components how I want them, now to cut and mount them up in 1mm or 2mm aluminum.


IMG_20121105_203900 by Splinter, on Flickr

I also got some time to put on the new handle bars with switch gear and the [url="http://www.jozztek.com/shop/throttles/44-billet-aluminium-throttle.html"]Jozztek throttle[/url].
It is starting to look really good, this coming week and weekend should have all the components fully mounted and my wiring loom starting.


Switch gear by Splinter, on Flickr


Right Hand Grip by Splinter, on Flickr


Overview by Splinter, on Flickr

[dr_frost_dk]

looking good, did not read the whole thread, but a good tip on cooling (if you didn't do LC) is to sand (fine) down the face off the motor and maybe in between if it is made like the 80/100 + apply cooling paste, this will pull heat out of the stator and windings, this has helped tremendous on my Electro Ciao and will let the motor handle more power and run cooler