Stand-up escooter, ze Meduza project

[agniusm]

Hi, need some help with connecting all the components. Basicaly regarding battery cut off switch and circuit breaker. Where is the best place on the circuit to place battery cut off switch, see the BMS picture, i think before it goes to BMS and controler and circuit breaker between controller and battery?
Thanx

[agniusm]

Here are some parts i have aquired:
12V 6A DC-DC

Charger:

Got some screws for building pouch cell pack, for the brass block:

[agniusm]

OK, got some time to work on battery pack. Starting to take shape, all the ideas turned out to be ok.
Using 6x6 @45mm brass blocks, half threaded 3M half drilled 3.5mm and countersunk 1mm deep. Bolts - 3mm DIN7991 Stainless Steel Alen head:

[agniusm]

Have rearranged battery for better BMS access if things go tits up:


 

Winter pleasures:

[agniusm]

Some updates:





Having issues with my BMS/charger. Here is my post from other thread:

Hi, found this thread by accident, thought will post here about my issue with this BMS and somebody might have a solution for me. I have all hooked up and it looks like BMS isnt working. When i connect + to BMS, charger kicks in for few seconds and goes out and after about 10 seconds dose same and stays off. When i hold + wire to bms between my hands (being bms in one hand, battery in the other) it starts working ok. It is some kind of mystery.
I am using it on a123 20Ah cells in 12s configuration with 5a charger. All cells range from 3.3 to 3.36 volts. Any input would be welcome.
Here are


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[agniusm]

Bought some LED lights. Will be using domestic 5W Edison bulbs, MR16.

10 degree for high beam:



38 degree for low beam



Heres how they look:



They fit near perfect in to those lights, just neet to cut out round perspex piece in front of the LED

[agniusm]

Charging cable:

[Brentis]

Have rearranged battery for better BMS access if things go tits up:


 

...

Following this thread,
I feel inspired to build my own pack now.

Keep up the great work.

[agniusm]

Thanx mate. Yea, spring is coming, need to finish it soon. The bike is gone to the painters, waiting or the spokes to arrive from TW, will need to lace two wheels, will be first time:)

[agniusm]

Got some work done. Still need to get the wheels trued.

[agniusm]

So looking like the project is coming to an end. Couple minor things to do. Have ordered this voltmeter of ebay:
 
Still need to make aluminium lid and a hatch for charging cable compartment, fit the voltmeter and front fender. Here are some photos:
 
 

[Uvedovle]

Great!

[agniusm]

Some more update:

Made covers:


DC-DC regulator and lights wire web

Bought old horn, rely funny sound but it fits:





Fitted horn :




To be continued..

[Astropower]

Very Clean and professional,

tell me please, how much weight all this scooter ?

[agniusm]

Thanx, i think it should be in 20-30 kg range, have not weighted yet

[agniusm]

Some final bits to finish:

Logo:

First coat for bottom + anti slip paint top


Before:

After

[agniusm]

Have done a test run. 100% throttle full time, 5W+ 1.5W LED always on. Top speed 32kmh, distance 33.67km. Here is Google KML file: https://docs.google.com/open?id=0B56NVZIdTBFOM19kUENJZERUeS1lQVJ0Z2REdnRPUQ
Maybe range will improve after couple full cycles as i have done just one, will see. Cheers

[EBJ]

looks great, but I just noticed you never braced that back post (where the coil-over attaches). Point a video camera at that part, then hit a bump and see how much deflection you get. I'm still concerned that is going to bend. Perhaps you can make a bolt-on brace if you didn't want to ruin the nice paint-job... ?

[agniusm]

Hi. Thanks for advice, and i did thought about it. Thing is 100+kg man was riding it half a mile on rough road and it was ok. Now my wife is 56kg which this bike is meant for so i am pretty confident, even me at 65kg feels solid

[EBJ]

good to know. now lets see some fun video footage of this thing!
(love the attention to detail... horn, kick-stand, lights, ect...)

[agniusm]

Here are some photos of finished scooter, i have done minor adjustments after to front fender, and still waiting on voltmeter which will go under ignition key.





Here is couple of vids:
My brother testing:

My wife:

Wifes friend

[Astropower]

Looks great,

Very high quality job you done.

[Brentis]

Great Job Bro.
Turned out real professional lookin'.
Monitor that seat post/batt. box joint for awhile.
Lots of inspiration to be had in this build.
Enjoy.

So what's next for ya?

[agniusm]

Thanx mate, glad you find something useful. Next, full scale production full suspension 70kmh cargo bike with recumbent seat and changeable base. But that wil be next year. First building a proper workshop and fitting new equipment, hopefully ESAB TIG in spring 2013.

[agniusm]

Done few upgrades:




Charging: