Hi guys,
I am in the process of reworking my commuter board and since I did not share the build process, I thought I might at least share the rebuild.
The specs now:
3x2s Zippy Compact 5.8Ah
Alienpower 7s 120A Sensored ESC
Alienpower 5065 270kv Sensored Motor
195mm Paris Trucks
5" Skike Wheels (modded)
~80cm Deck lenght
Custom split aluminum enclosure
Turnigy 'poor man's BMS'
Wiiceiver+Nyko Kama
Charging/Balancing via 9pin DSUB connector
Switches for light, 'bms', antispark, EC5 Loop as main switch
Problems with the current setup:
Don't want to leave lipos charing unobserved
battery tends to unbalance
battery cant be swapped easily , I don't have a 2nd one
enclosure is not as enclosed as I would like
shitty griptape (minor problem, but still sucks!)
messy wiring so I never want to open the enclosure again for checks
I am scared of inbus head bolts stripping
Things I want to change:
switch to 18650 konion cells salvaged from makita packs bought from doctorbass
make an easily swappable battery 'ebike style'
get rid of the poor man's bms
change to VESC for testing
get rid of the EC5 loop, momentary switch and bms switch
add a proper switch when back in stock at APS or vedder develops one
change to XLR 3pin plug for charging
swap some of the higher stressed bolts to TX
Rebuilding the enclosure
I will be making a two part enclosure, one part containing the batteries and charge (xlr) and discharge (EC5) ports, the other one containing VESC and other stuff being sligthly larger so the battery one will slip about 2cm inside and connect the discharge port. The VESC enclosure will be permanently fixed to the board, the battery one will attach via clips to the VESC one and the board and be interchangeable on the go.
The battery enclosure will fit 24 cells in 6s 4p config to allow 40amp burst current, so about 1kw from that motor (which is enough power for a commuter imo). It will only offer 200mAh more than the current battery (which probably gets negated by using used cells) but I will be able to carry a 2nd or even 3rd pack in my backpack for super long range)
For the material, I see three options:
glass fibre
wood
abs
I tried glass fibre, but without a strong vacuum equipment, it will get uneven corners (check the upper left on the router pic below to see my gf experiment with wrinkles) where the fibres fold over and I need a clean outside surface to fit the stub end of the smaller enclosure into the ESC/Electronics one.
Abs requires an oven and i do not have it handy.
So I ended up shaping a wooden enclosure around a mold with a flush trim bit and angled plate on my router. After the mess I made in my workshop, maybe getting an oven or vacuum equipment would not be too bad at the end.. will see how the result turns out.
Slightly oversized 3mm plywood sheets were attached to the mold with double sided tape and trimmed (no sheet on in the pic).
Covered the mold in kitchen cling wrap to protect it from epoxy. Forgot to take a pic, but added strips of GF on the corners to make stronger joints.
Everything taped up and drying, will see how it turns out tomorrow.
Will probably cover the enclosure with thin CF just for a little stability and looks (just like the board).
What do you guys think?
Two things I am not sure about yet: What is the pin spacing for the JSt connectors on the VESC and the sensor wires of the 5065 270kv Alien sensored motor. Can anyone tell me?
I am in the process of reworking my commuter board and since I did not share the build process, I thought I might at least share the rebuild.
The specs now:
3x2s Zippy Compact 5.8Ah
Alienpower 7s 120A Sensored ESC
Alienpower 5065 270kv Sensored Motor
195mm Paris Trucks
5" Skike Wheels (modded)
~80cm Deck lenght
Custom split aluminum enclosure
Turnigy 'poor man's BMS'
Wiiceiver+Nyko Kama
Charging/Balancing via 9pin DSUB connector
Switches for light, 'bms', antispark, EC5 Loop as main switch
Problems with the current setup:
Don't want to leave lipos charing unobserved
battery tends to unbalance
battery cant be swapped easily , I don't have a 2nd one
enclosure is not as enclosed as I would like
shitty griptape (minor problem, but still sucks!)
messy wiring so I never want to open the enclosure again for checks
I am scared of inbus head bolts stripping
Things I want to change:
switch to 18650 konion cells salvaged from makita packs bought from doctorbass
make an easily swappable battery 'ebike style'
get rid of the poor man's bms
change to VESC for testing
get rid of the EC5 loop, momentary switch and bms switch
add a proper switch when back in stock at APS or vedder develops one
change to XLR 3pin plug for charging
swap some of the higher stressed bolts to TX
Rebuilding the enclosure
I will be making a two part enclosure, one part containing the batteries and charge (xlr) and discharge (EC5) ports, the other one containing VESC and other stuff being sligthly larger so the battery one will slip about 2cm inside and connect the discharge port. The VESC enclosure will be permanently fixed to the board, the battery one will attach via clips to the VESC one and the board and be interchangeable on the go.
The battery enclosure will fit 24 cells in 6s 4p config to allow 40amp burst current, so about 1kw from that motor (which is enough power for a commuter imo). It will only offer 200mAh more than the current battery (which probably gets negated by using used cells) but I will be able to carry a 2nd or even 3rd pack in my backpack for super long range)
For the material, I see three options:
glass fibre
wood
abs
I tried glass fibre, but without a strong vacuum equipment, it will get uneven corners (check the upper left on the router pic below to see my gf experiment with wrinkles) where the fibres fold over and I need a clean outside surface to fit the stub end of the smaller enclosure into the ESC/Electronics one.
Abs requires an oven and i do not have it handy.
So I ended up shaping a wooden enclosure around a mold with a flush trim bit and angled plate on my router. After the mess I made in my workshop, maybe getting an oven or vacuum equipment would not be too bad at the end.. will see how the result turns out.
Slightly oversized 3mm plywood sheets were attached to the mold with double sided tape and trimmed (no sheet on in the pic).
Covered the mold in kitchen cling wrap to protect it from epoxy. Forgot to take a pic, but added strips of GF on the corners to make stronger joints.
Everything taped up and drying, will see how it turns out tomorrow.
Will probably cover the enclosure with thin CF just for a little stability and looks (just like the board).
What do you guys think?
Two things I am not sure about yet: What is the pin spacing for the JSt connectors on the VESC and the sensor wires of the 5065 270kv Alien sensored motor. Can anyone tell me?