Modifying Norco frame.. need advice

[dogman]

Well, that shoehorned in there much better than I thought possible. Looking at just the pic, I was thinking no way unless you went to a smaller controller.

Well done!

[iovaykind]

It's alive!

All I have left to do (which is an understatement) is to finish off the pack. Whether or not the batteries will fit well is still up in the air with all the wiring mess going on. And hopefully spray foam will keep everything in its place while providing some cushioning.

[iovaykind]

Some updated pics to get people to read this thread..:




Need help with soldering lipo tabs.. how do you guys do it? I can't seem to get the solder to adhere to the tabs.. Now I'm stuck with a 12S setup with no clue how to get the last four cells in series..

Edit:
With the remaining solder on the tabs, I was able to finish wiring all the batteries in series. Now to wait on the balance plug..

Another issue I foresee is the regen.. I'm seeing peak of 30A.. which is 6C charge rate o_0 that can't be good for the batteries. Will need to figure out how to lower the regen power or think about increasing the capacity to 10ah by fitting lipos under the frame. Lose stealth if I do that

[iovaykind]

My big mess of wires that makes my lipo look like a bomb.

Scratch that.. it IS a bomb.

Trying hard to get it to fit in:

Had problems so had to cut out the extra panel to fit everything.

Big mess, needed to relocate capacitors, and sliding in batteries was a huge feat.


But FINALLY it all fit:


Thanks to those who believed it could happen, and hi haters to those who didn't. Just kidding,


There's really like no space left.. I'm going have trouble fitting any sort of switch to turn it on. Will have to devise something, but will remain as stealth as possible! Going to get covers fitted so the bike looks normal again. Cheers!

[doc007]

WOW!!

That is an amazing build. So clean, so stealth. Good job man!

Can't wait to check her out. The GoPro is waiting.

Hope you get that balance plug soon!!

Congrats!

ps. make sure you dont short anything out on the metal frame. ALL that hard work and money would go down in a flame of glory. Maybe a coat of rubberized spray (plastic dip) might help.

[whereswally606]

iovay, thats impressive, i'm surprised and worried about how much weaker taking that second panel out has made the frame? my norco's do, have as much internal space as this so id have to resort to long packs , not sure im going to bother till i get one of a very similar style or make my own.

regards Andy

[iovaykind]

The frame is still pretty darn strong.. I wouldn't by any means jump this off anything significant, but off the curb no problem and can probably handle some small jumps. What's good about this aluminum is that even if a jump were to exceed its tensile strength, the frame would bend, but it would never snap. After removing the panels, I went ahead to test the material, and 6061 alloy is really good stuff.

I hope to close this bad boy up soon after I get the balance plug, install some charging wires, and a switch. Finding a spot for this stuff will be an issue now

[BATFINK]

Very nice build I have an older but almost identical frame. The frame i have also has What size is your frame?

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[iovaykind]

This one is a medium

[BATFINK]

Cheers, what voltage and amps are you running? Did you make those batteries yourself to fit that frame using cells or did you start with lipo. Bricks and modify them?

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[iovaykind]

I'm running 16s lipo (~66.5v fully charged 4.16v/cell) and this controller is running around 50amps on my 5ah pack. Thinking about making a removable 16s5ah pack to fit onto the bottom of the frame.

Used 4s hardcase packs and had to rewire it into 3s packs, with 1 cell by itself near the controller

[smudger1956]

Well thought out mate, well impressed with your 'stealth install'.

[BATFINK]

Thanks man, I'm going to follow your lead with this with a little more modification of the frame and pack loads a lipo in there, I need about 20/30amps or I might do 15amps and I have a battery in my backpack at 48volts 20 amps I can hot swap if going longer distances. Well done. Looking forward to seeing it all closed up and stealthy so post your pix soon

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[BATFINK]

I have a freeload rack, that can fit on the rear of the bike and you could easily clip it off and on if you needed to carry more battery on longer journeys, my rack is like this: http://www.freeload.co.nz/store/0/3/Sport-rack

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[veloman]

Talk about smart use of space. Great job.

[BATFINK]

Any updates on your finished bike?