Okay time for an update on the bike. I thought I would improve my battery enclosure. First I was going to do s sheet metal job, but thought it would all look too boxy. Then I got inspired by a beautiful Cannondale conversion
and was planning to go the full fiberglass box in the triangle, even bought the foam and started to shaping it. But with the width of my battery pack I could decide on a nice shape for it, so ended up doing something a bit different. Here are a few pics of how it all turned out.
So it isan old backpack reborn as an enclosure for the battery, controller, DC-DC converter and general wiring.
It still has the same sheet metal support I was previously using, but hopefully looks less like a garbage bag than before
Everything is still narrow enough to only brush my calves occasionally during pedaling.
Here's a closer look with the hood up. It is all a nice snug fit. I made a nice cable exit out of the top of the back face of the bag for the phase, hall and rear blinky light wires. At the moment I have the throttle, CA and headlights wires just exiting the zip at the front, But I might clean this up.
After a few stacks in the wet when I have locked up the front due to poor modulation of the brakes. I decided to put some Avid BB7 on the front, got a second set for the rear but they didn't fit.
Also got some cheap mud guards and a rear rack with kiddy seat so I can take my three year old on the bike. First time I took him on he kept say "Slow down daddy." Now he says "Faster Daddy. The cars are catching us!" Kids are great.
Not sure if I mentioned it before but I have now got my dual Cree R2 headlights, and a blinky red rear light all hooked up to a DC-DC converter off the main pack. I also mounted a switch in the CA that switches on th e CA backlight, headlights and tail light at once. Here is a pic:
Finally I also now have the CA throttle over-ride rigged up to limit amps to 25. This makes for a little less vibration during dead stop starts, and seems to have stopped the BMS from its occasionally tripping.
Have now racked up around 2800kms, and ride every day to work. Perhaps now that I can lock up the electronics a bit more securely, I'll start using it more where I have to lock it up in public.