Another RG250 with Colossus Motor

[Arlo1]

And anyway i still dont think its that hard for controller ; 36 fet- working and tested , splinter kelly working, my kelly - working, new sinewave contrl - will work - i think well check it at saturday....

Yeh but its a shame to run with these little controllers. We need a 50kw controller for it. Then we can see the real power! We need epic phase amps! Im working on it buddy

[gwhy!]

And anyway i still dont think its that hard for controller ; 36 fet- working and tested , splinter kelly working, my kelly - working, new sinewave contrl - will work - i think well check it at saturday....

Yeh but its a shame to run with these little controllers. We need a 50kw controller for it. Then we can see the real power! We need epic phase amps! Im working on it buddy

I have worked on it but need a motor to test it

[Arlo1]

Gwhy. Post your controller build on my not simple diy controller thread.

[gwhy!]

Gwhy. Post your controller build on my not simple diy controller thread.

I will post all details when Im happy with it..

[Arlo1]

Gwhy. Post your controller build on my not simple diy controller thread.

I will post all details when Im happy with it..

Can you pm me how its going and any details?

[Whiplash]

Gwhy, this is the last thing you need! LOL! Your friggin little $50 motor does the same speed this big one does! If you get a hold of it you'll kill yourself! HAHA!

EPIC build here mate!! I would LOVE to do something like this, but I am barely on a bicycle budget, let alone a Motorcycle!

[Arlo1]

Gwhy. Post your controller build on my not simple diy controller thread.

I will post all details when Im happy with it..

Please.... I will give you a good deal when I am a North american collossus dealer!

[SplinterOz]

Ok just a few tweaks. I put on the timing adjuster and have reduced the amp draw at full rpm. I have also changed the motor current settings and gained a little more acceleration and speed. Now uses about 100amps (battery) and gets up to about 85km/h. I should be getting the battery mounting gear soon. Then we should be cooking with gas

[jonescg]

This will require a test ride tomorrow, you know

See you about 11 am or midday?

[SplinterOz]

Any time and yes a ride is in order

[SplinterOz]

Here is the bike running.

Note the 1030 is the battery Amps multiplied by 10, using a neat gizmo from Zeva to drive the tacho.

So for the hard of seeing...
78km/h
67 Volts (boy these headways sag)
103 amps

This makes for 6.9Kw for 78Km/h not too bad.

[SplinterOz]

The guy that has working with me on the design and fab work has given me the first draft of the battery layout.
I am going to be running 120 10Ah Headway cells in at 24S5P setup. Due to the constraints of the frame I will be building the pack as a "stepped" pack with a double width section and a single width section.

Four plates will be created to hold the cells. The inner plates will hold the ends of the single cells and support the middle of the double width cells.

[markobetti]

The guy that has working with me on the design and fab work has given me the first draft of the battery layout.
I am going to be running 120 10Ah Headway cells in at 24S5P setup. Due to the constraints of the frame I will be building the pack as a "stepped" pack with a double width section and a single width section.

Four plates will be created to hold the cells. The inner plates will hold the ends of the single cells and support the middle of the double width cells.

I like the idea for holding cells, and also the motor mount - i dont know if i said this before, but that cnc design is designed nicelly . Your design or tool-mans ?

[SplinterOz]

I like the idea for holding cells, and also the motor mount - i dont know if i said this before, but that cnc design is designed nicelly . Your design or tool-mans ?

The fabrication work is being done by a local company Mobile Fabrications. Luke there has done all the design work and either at his shop or his contacts all the work is being done. Toolman2 is helping with all the motor and controller setup. Without them the whole build would be sh*t.

Luke has a great eye for the design and layout.

[markobetti]

REALLY ? well done Luke. If its open info ; what was the price for that piece of art ?

[SplinterOz]

REALLY ? well done Luke. If its open info ; what was the price for that piece of art ?

Luke has been doing a lot of his time for free as he likes this stuff and doesn't get enough. Getting the 4 plates CNC'd out of the plastic and the material will be about $780AUD. Luke has spent about 5 hours or so at normally $100AUD an hour.

So far all the work Mobile Fabrications has done (Sand Blast and powder coat the wheels, design and build motor mount, design and build sprocket carrier, design and build rear disk carrier) has been about $1700AUD. Not cheap but much better quality than I can do.

[markobetti]

wow , more expensive than the motor...But i agreee quality seems great and the design also

[voicecoils]

That motor mount is a work of art to see in person.

The headway cell holder design looks great too. Have you settled on a material to do them in?

Great progress Tony!

[Philistine]

I went over on the weekend and got to see it in person, also got to meet Chris and his bike. Only got to see Tony's bike in action though as Chris and Tony were de-agniing Chris's bike.

I was very impressed to see Tony's bike in action, it is going to turn heads around quiet old Canberra I dare say (amongst motorcycle enthusiasts anyway). The Colussus is an impressive motor.

I felt very emasculated by a Colussus and Twin Agni bikes with my 3kw frock Greyborg. Great stuff.

Phil.

[Goped ESR750]

REALLY ? well done Luke. If its open info ; what was the price for that piece of art ?

Luke has been doing a lot of his time for free as he likes this stuff and doesn't get enough. Getting the 4 plates CNC'd out of the plastic and the material will be about $780AUD. Luke has spent about 5 hours or so at normally $100AUD an hour.

So far all the work Mobile Fabrications has done (Sand Blast and powder coat the wheels, design and build motor mount, design and build sprocket carrier, design and build rear disk carrier) has been about $1700AUD. Not cheap but much better quality than I can do.

wow. Thats pricey. I love the motor mount though.

Do have the space for machine tools at home. You probably could a got a decent size lathe and mill and machined your own parts manually. I tried to manually make as much possible. Save so much money, I have access to huge lathes and mills though, which is a great bonus.

[SplinterOz]

Thanks for the compliments on the work, I will pass them on to Luke.

I do have some room at home for tools, but I think buying a lathe, mill, drill press, 3d software etc to build one bike would not be economical. My machining skills are limited at best so I would probably use twice the materials and I will still have to seek help for the design work.

If my plan was to build multiple bikes or do continuous improvement on this bike then buying the gear might be worth it, however I want a nice electric bike to ride every day and other than the Zero none are on sale in Australia.

[SplinterOz]

Today I got my new front disc brakes from Metalgear up in Queensland. They take the mounts from mine and attach new rotors. They look good and make me feel a lot better about the braking setup.


New Discs by Splinter, on Flickr

I have also fitted a temp sensor into the motor that will work with the Kelly controller. Originally this prototype had a cheap thermistor that was wired incorrectly. The new sensor is amongst the coils and should detect the temperature very accurately. I have also recovered the wired coming out of the motor for all the sensor wires.


New Temp Sensor by Splinter, on Flickr


New Temp Sensor by Splinter, on Flickr

So far for this motor I have repositioned all the Hall sensors, replaced the temp sensor, rerun the sensor wires, and changed all the bearings. I will be re-assembling it for the last time over the next week (work permitting) and it will be mounted in the bike never to be removed again (unless I get a production version soon).

[Jay64]

Sorry, I must have missed it. Which Kelly controller are you using for the big colossus? I'm guessing that if it can handle that motor, it should definitely be able to handle my 7kw colossus motor.

[SplinterOz]

I am using the KBL72501B controller from Kelly, 500amp peak 72 volts nominal. Seems to be handling things well.
NOTE: I did get the High Speed option.

[Arlo1]

I am using the KBL72501B controller from Kelly, 500amp peak 72 volts nominal. Seems to be handling things well.
NOTE: I did get the High Speed option.

Come on crank it up all ready! I want to see someone make this motor rip!