Electric Race Bike

[jonescg]

Dude, you have so much spare room in there you can store a spare helmet and some tyre warmers!!

[Jay64]

I overlayed the gas bike pic over the sketchup frame and everything. The frames were lining up pretty well. But Now that I'm done and looking at it from a different perspective, I think the motors and batteries are not to scale for the frame. I don't think there will be that much room. But at this point, I just wanted to get a good look at the '06 frame/bodywork mocked up.

[Jay64]

This is the actual size of the Agni in the '08 frame.

[Jay64]

My postman has been busy lately. Just got the 80 balance plugs and gold bullet connectors and a few emergency cut off switches.

[mauimart]

Great progress on the build. I would like to do a motorbike build with my students next year. I was thinking an on/off road/enduro type frame with the 20Ah A123 cells and a Perm132 motor. We might even design and build the frame from scratch if we can't find a decent donor (hard to come by donor bikes on Maui). In any event your build is very inspirational.
Martin

[Jay64]

If you are serious about looking for a donor bike, let me know. I got a bunch of friends on the island who ride. We could probably find you something. I know my buddy on Oahu has a KTM chassis he is trying to get me to buy for an EV build.

[mauimart]

PM sent.

If you are serious about looking for a donor bike, let me know. I got a bunch of friends on the island who ride. We could probably find you something. I know my buddy on Oahu has a KTM chassis he is trying to get me to buy for an EV build.

[Jay64]

It's official, my entry is in to race the whole season of the North American TTXGP Championship. Only bad part is that there is a race at PIR in Portland that conflicts with the AMA Pro Racings race at Barber in Alabama the same weekend. I'm probably going to have to skip that PIR race.

And I was able to secure my race number 64 too!

[sflorlando]

Wow congrats

[Thud]

Great news Jay!
You know we'r rooting for you.
(we'll all be looking for that endless sphere sticker in the photo's LOL!)

[Jay64]

Great news Jay!
You know we'r rooting for you.
(we'll all be looking for that endless sphere sticker in the photo's LOL!)

I got some endless-sphere stickers, but they are bicycle sized. Anyone got any larger ones?

[Jay64]

I had to pause my build to run up to Road Atlanta for my ICE racing series. Back in town and back on the build. I came home to a package from Methods with a bunch of BMS stuff.

methtek.jpg (97.6 KiB) Viewed 356 times

methtek2.jpg (54 KiB) Viewed 356 times

Methods, thank you so much for the expedited work on getting these out to me.

[drewjet]

Looking good Jay, how are those battery boxes coming along?

[Jay64]

I made the mistake of gluing the first one together before I remembered that we had only done the cut outs for that one. I had forgot that I was supposed to use the pieces as patterns for the second box.

But on a positive note, I went down to my local plastics store and the Weld-On 3 glue that I got for the plexiglass way back when also works on Lexan, so I got a ton of that stuff to use and didn't have to buy any more.

Oops, forgot the pic.

battery box.jpg (49.6 KiB) Viewed 353 times

[drewjet]

Looks good. Fortunatley it is clear plastic and you should be able to copy them by laying on top.

Got the bike striped down yet?

[Jay64]

Yeah, I stipped it down before I left for the races in Atlanta. I dropped it off at off the grid. One of the guys that is living there is taking a machining class and wants to help make the motor/battery cage.

[fechter]

I got some endless-sphere stickers, but they are bicycle sized. Anyone got any larger ones?

Here is the image file. A laser printer, some blank label stock and you can make your own any size.

ES logo.jpg (89.68 KiB) Viewed 334 times

[Jay64]

Would two of these work for a charging solution for a 168v pack? Looks like I would be able to charge at 9A.

http://www.bmsbattery.com/alloy-shell/28-alloy-shell-900w-lifepo4li-ionlead-acid-battery-ev-charger.html

[voicecoils]

Would two of these work for a charging solution for a 168v pack? Looks like I would be able to charge at 9A.

http://www.bmsbattery.com/alloy-shell/28-alloy-shell-900w-lifepo4li-ionlead-acid-battery-ev-charger.html

Splitting pack or chargers in series? Both would probably work. Not amazing units though, I have one and several other BMSBattery chargers. They're economical bulk chargers but I wouldn't bet a race on it actually switching on each time before the next race.

You'd be much better of with something like this:

http://www.russcoev.com

5,000W max charge power. Fully adjustable current (0-30A) and voltage (80-225v). $1k, made in USA, American warranty.

Adjustable current is real handy to max out the power from the wall without tripping circuit breakers.

You'll need fast charging or you'll lose track time, especially practice sessions.

[etard]

That is an impressively small charger! I could even see strapping that thing on the bike and taking it with you on long trips.

[drewjet]

That is an impressive charger. Should get you charged in less than 2 hours.

[Jay64]

Yes, that is an impressive charger. Unfortunately at this moment, I don't have $1000 for a charger. I've already spent over $5k in the last 15 days for parts on the bike, not to mention the $3200 for the season entry. And I'm still paying for my ICE racing in the mean time as well. I might get that charger at some point this year, but I can't afford it right now before the race in 9 days.

[fechter]

Would two of these work for a charging solution for a 168v pack? Looks like I would be able to charge at 9A.

http://www.bmsbattery.com/alloy-shell/28-alloy-shell-900w-lifepo4li-ionlead-acid-battery-ev-charger.html

Well, much more economical than the Russco unit anyway. Get what you pay for. I don't see why those wouldn't work. Tapping the pack midway and using them in tandem is probably safer. I don't know for sure those have isolated outputs, so that would be important to know. I have seen some reports of them releasing smoke during use, so best to have a spare one. If the pack is tapped midway, it's possible to charge each half separately with one charger in the event one quits working.

168v is really close to what you'd get if you just put 120 vac through a bridge rectifier. Bad boy charger?

[voicecoils]

Would two of these work for a charging solution for a 168v pack? Looks like I would be able to charge at 9A.

http://www.bmsbattery.com/alloy-shell/28-alloy-shell-900w-lifepo4li-ionlead-acid-battery-ev-charger.html

Well, much more economical than the Russco unit anyway. Get what you pay for. I don't see why those wouldn't work. Tapping the pack midway and using them in tandem is probably safer. I don't know for sure those have isolated outputs, so that would be important to know. I have seen some reports of them releasing smoke during use, so best to have a spare one. If the pack is tapped midway, it's possible to charge each half separately with one charger in the event one quits working.

168v is really close to what you'd get if you just put 120 vac through a bridge rectifier. Bad boy charger?

Yeah, cheaper. I have one & it puts out ~700W, not 900W it's rated for. Buy at least 3 (1 spare) and expect about $200 for shipping = $440. They also build to order so expect about 2 weeks till it arrives.

Maybe someone local will lend a Zivan, DeltaQ or Manzanita micro. Hit up your local EV car group?

[Jay64]

2 week lead time won't work. I thought I heard someone say they got it at their doorstep in less than a week.

Fechter, I'm down for a bad boy charger. How would one go about putting it through a bridge rectifier?

Anyone in Nor Cal willing to lend me a charger for the weekend?