NEM0 - <$1k Electric Dual Sport

[captainslug]

Very nice build up, I like the modular aspect of your construction. From motors to batteries, converters etc.
I was curious, what is the make/ model of the base frame. I looked but could not find that information.

Skubadu

Xmotos XB-31XT

[captainslug]

I'm changing the chain transmission axle to a 5/8" OD keyed shaft, so I had to change out the bearings. I'm waiting for a replacement freewheel adapter to come in the mail.

All of the wiring is finished, as are the turn signals.

Front fender is almost done.


Rear mud guard

[captainslug]

More progress and the first rolling tests.
Here's what the "gas tank" looks like when it's charging.

I think I like the fender more this way.

I tested outside at low speeds. It's currently blowing the 30amp drive fuse under normal accelerations. So I'm going to replace it with an 80VDC 50amp circuit breaker.

[captainslug]

Success today.

Installed an 80VDC 50AMP circuit breaker to replace the 30amp fuse holder.

I then went for a test ride and managed to get up to 30mph. However the motor got pretty toasty so I'll need to add active cooling.

[gogo]

Nice!

I had occasion to look up the federal requirements for vehicle lighting some twenty years ago. I found them in the Arizona State University library. If I remember correctly you need passive reflectors, amber in front and red in back, and powered lights that can be seen from a specified distance from the side and the back. You aren't required to have turn signals on a motorcycle, but they must be amber after 1970-something if you have them.

I'll see if I can scare the information up using the internet now. There are many of us doing similar one-off builds that could benefit from being able to cite the specific law.

[captainslug]

Chain tensioner added to first reduction. Works beautifully.

I need to make a mounting plate so I can attach this temperature-controlled blower fan as shown.

It handles really well. I'm actually surprised by how comfortable it is.

[captainslug]

When trying to pull or push air through such a restrictive space a centrifugal fan will always work best because it will be capable of higher static pressures. Which is why you got better results with the squirrel cage fan as opposed to the axial fans.
I'll see if the one I have works. If not then I'll have to do some shopping around.

[captainslug]

Spacer plate for the blower fan.

Blower fan installed. Does a fine job of keeping the motor at reasonable temperature levels.

I ended up making a chain pad since I couldn't find a replacement one anywhere.


Rode it 5 miles today. Performs really well.
Next step is to replace the battery pack and controller wiring with a higher wire gauge so I can remove the circuit breaker (or get one with a higher rating).

[captainslug]

[gogo]

That is a tight build you have there.

I hope you don't take offence to my posting the federal lighting requirements link here. Shortly after looking this stuff up back in the 80's, I got pulled over because my turn signal lens was "too white". Nevermind that I was driving an old stock Renault station wagon in Arizona where the sun regularly fades everything, the police had been told they could pull over those punk customizers with the custom white lens covers. Having just read the code, I knew I was technically in violation.

So here's the link to the code in case you want to be able to argue your case with the authorities.
http://edocket.access.gpo.gov/cfr_2004/octqtr/49cfr571.108.htm

Just use motorcycle as your search word within the document. Man, I wish I could have done that back in the 80's.

[captainslug]

Actually I'm about to switch back the turn signals back to white LEDs behind fluorescent orange acrylic lenses. The amber LEDs just don't seem bright enough to me.
I do need to add reflectors though. Not that I've ever been pulled over for having lacked them.

[captainslug]

Good day followed by a rough night.

Replaced all of the battery pack wire with 6awg with Anderson powerpole connectors because the two-pin connectors were starting to melt.

Went for two 8 mile trips today. The motor was overheating a good deal and it got so hot on the trip back that I had to pull over.

I'm not sure what I'm going to do. I'll have to think about ways to add more effective cooling, or try to find an alternate motor.

[recumpence]

Motor efficiency is such that you can only do just so much without reducing your power pull from it, or moving to a different motor.

With a bike that size, that motor is really too weak. However, the build is so beautiful, I would hate to see it hacked uyp to replace the motor.

I would recommend an RC motor. But, RC controllers take a beating if you cannot pedal first.

Hmm, what other motors are you looking at?

Matt

[captainslug]

Hmm, what other motors are you looking at?

I was looking at the Currie 1000w 36v motor, but no stores stock it at the moment and the shaft on it is way too short.
For now I'm going to try taking my current motor apart, drill a bunch of holes in the steel housing, and add three crossflow or blower fans so I can cool the rotor directly.

If that doesn't work then I'll probably end up using the same motor FrankG has now, albeit in single and at a higher voltage/wattage.

[boostjuice]

Dont buy another underpowered Chinese rubbish motor....it doesn't do the rest of the bike justice.

An RC motor would be a superior choice if the bike was designed around one from the outset, but to maintain similar gearing and layout maybe one of these?

http://www.lmcltd.net/index.php?page=motors-and-generators-2

Don't you think such a quality project deserves a little more quality/costly motor? Your time alone in machining all the lovely parts would definately equate to >$1000. Go on... spoil her

[captainslug]

The MY1020 is full of soot and the epoxy came dislodged from the rotor. I'm going to give up on it and switch to the MY1020Z3, which I will have to add a freewheel adapter to.

Don't you think such a quality project deserves a little more quality/costly motor? Your time alone in machining all the lovely parts would definately equate to >$1000. Go on... spoil her

I don't have that kind of money right now.

[captainslug]

I've made a ton of progress since the last update, but haven't had a camera handy to record any of the specifics. Expect a large update before this weekend.

[voicecoils]

I've made a ton of progress since the last update, but haven't had a camera handy to record any of the specifics. Expect a large update before this weekend.

Looking forward to it captainslug!

You've done an awesome job already.

[recumpence]

Excellent! Keep the pics coming!

I love this build.

Matt

[captainslug]

Here's everything I've done in the past month. I apologize for not being able to take in-progress shots, but my camera took an accidental vacation in China because my boss mistook it for his.

+ I bought a 5/8" ID steel freewheel adapter from Staton Inc.,
+ I used the lathe to bore the ID out to match the motor axle size.
+ The #40 double-D-bore sprocket included with the motor was ground down to make a washer.
+ Washer was then TIG welded onto the freewheel adapter.
+ I drilled the hole pattern into the #35 sprockets, then used a bolt to chuck in the lathe so I could cut out the large center hole.
+ I made a motor-mount plate out of 1/4" polycarbonate, and end brackets out of 1" aluminum square tube.


The sprockets are bolted onto the opposite sides freewheels so I could attach the motors to the motor mount plate at an offset. This allowed me to overlap the gear case of the top motor over the cover of the lower motor.

See below image showing where I had to grind both.

Doing this save me just enough space so that I had more than enough clearance between the frame and the top side of the chain.

I also drilled out and cut square notches in the mounting holes.
I thought I was going to have to offset the brushes 90 degrees to reverse the motors, but it turns out the motors spin the right way around when stock.
Wasted effort on my part, but at least I had the option of reversing them later on.

The problem I have now is that the sprocket on the lower motor isn't engaging enough teeth and slips on the chain. I may have to move the upper motor to the swing arm, or remount the lower motor after rotating the gear box position.

Left to do
1. Fix chain slip
2. Make new brake light
3. Make new turn signals (front and back)
4. Record a video for everyone that has been nagging me to

[drewbird911]

Great Up Date and Project, very nice work! How are you on the <$1,000 point?

[toyguru]

Have you got enough room to add a second chain, have a double sprocket on the bottom motor, have a chain from top motor to bottom motor, and then a chain from bottom motor to rear sprocket?

[captainslug]

Have you got enough room to add a second chain, have a double sprocket on the bottom motor, have a chain from top motor to bottom motor, and then a chain from bottom motor to rear sprocket?

That will actually work, but the sprockets will have to be bolted together onto the freewheel with spacers between them.

Great Up Date and Project, very nice work! How are you on the <$1,000 point?

Over budget by $500.

[toyguru]

That will actually work, but the sprockets will have to be bolted together onto the freewheel with spacers between them.

Seeing what you've built already, I don't think that would be too hard for you

[captainslug]

I'm working on a fake exhaust that is in fact a brake light.