72v PSI leggo - X5304 Chopper

[Ypedal]

I"m finally taking the time to build up my chopper once again !

The X5305 with 48v 12ah prismatic cells was ok last year but the 12ah cells are fizzing out and they are dying one at a time making the chopper a sitting duck, and on top of that the X5304 i built for my Norco did not work out so well either after it pulled itself out of the frame....... so it's chopper upgrade time !

I got my Leggo's from "AndyH" on this forum,
http://www.rechargeablelithiumpower.com ... /index.php

The cells themselves i got direct from PSI in taiwan last year..

So let's begin !

I've decided to build the pack in 12v blocks, given my history of relocating bits and pieces to different projects as i burn things up ..

[Ypedal]

The blocks are incredibly well made, sturdy, strong, low flex, and they lock together very tightly

After lining up the notches, i used a block of nylon and a hammer to set them in place..

[Ypedal]

I dug thru my stash of carboard and found the template i made last year when building the 12ah pack.. as you can see, the 6 x 12v packs will fit in the frame perfectly with not much room to spare once i add sides to the packs..

[Sacman]

Hi Gaston,

So the cells will sit perpendicular to the frame? Those cells about 6-inches long right? Add another inch for the plastic legos... that's about 7-inches wide you gotta straddle your legs around to pedal. Oh I see the chopper no pedals... just foot pegs.

What are you gonna do to support the individual 12-volt packs appart from each other? You gonna have a board or cover of some sort at the ends? Looks like you can even fit your controller in that triangle if you arrange your 12-volt packs closer to each other.

[deecanio]

nice.

i got my bms from AndyH top guy
so whats happening with the dually and wheres the badassical dh'er? eh? eh?


D

[Ypedal]

Sacman : Alot of unknowns lol... i figure it out as i go .. .. i measured the assembled 12v pack and with end plates etc it will be 7.5" long, and that's correct, no pedals.. just footpegs.

D : The Norco is screwed, needs a new swingarm( fudged the dropouts with an X5 !! .. ouch ) .. i'm ordering a new swingarm from the local bike shop if we can work it out somehow, i'm admitting to personal stupidity and not trying to go for a warranty claim.. it is my fault. The Dualy will end up either on the norco if i can get a new swingarm, or on the TF frame once i buy a front end for it ( trying to find a good deal on a tripple crown fork with front 24" and disk )

--

as per " BMI " in the battery section of the forum, one layer of electrical tape and the cells wedge right into the blocks..

[Ypedal]

one side :

[Ypedal]

Cha Ching !

I started the electrical tape between the white barcode sticker and the cell's shrink wrap stamp, this way the stickers and tape seams all point in the middle and out of sight ! ( OCD ?? )

[Ypedal]

top view

[Ypedal]

And this time i'm using a BMS !!! ( or " vms " .. )

[Ypedal]

The packs need to allow for the ballancing wires and i don't want to make them any wider than needed ( I have no spare room !! ) .. so using a 9/64 bit drilled thru one of the corner holes !!!

[Ypedal]

On the back side of each block, one corner has a bigger space, perfect for fitting 3 wires !

[Link]

Methinks Ypedal has uncovered a design improvement...

[deecanio]

nice work on the psi's Y.
major bummer on the norco (just caught up on that) hopefully you can get a replacement swingarm for her.
If the norco is a no go can't you use the duallys on that on the tf?


D

[rkosiorek]

Each of the 4 -cell boards has a little LED fuel gauge. will those be visible?

rick