Suzuki GT50 Conversion

[bzhwindtalker]

whoa! it's Christmas Lot of good stuff here, arduinos are so much fun!
I also really like your ev moto concept, it reminds me of a honda pbr!
Do you plan on swapping the electronics, motor and batts over a more sporty chassis when the bike will be debugged?

All the best
Adam

[only1jake]

Haha, Christmas it sure is. That concept was done on sketch-up quite a while ago. Although I downloaded the body and put electrics in. There's quite a few available to download for free.
I don't think so. At the moment I really like having a quick little bike. I am going to register it as a motorcycle hopefully. Yeah, I think I'm going to stick with this bike. Needs lots of work still. Once I have everything mounted and batteries, I will tear it down and sand and paint the frame etc. It's pretty rusty. My order from ebikes.ca just arrived.. I'll take photos later and I'll hook it up to the logger and get testing.

Jake

[only1jake]

So this morning my cycle analyst arrived. High current version. Here are some photos of the insides and hooked up to the logger. Pretty easy install. Logged data well too. I tested with 2 9v batteries in series haha. I also Sealed the logger and cycle analyst for the wellington weather





Plus, how to connect the logger to the computer to charge and the settings.






Yes that it a verti-go in the background

Jake

[only1jake]

Sooooooooo.... I did a little log this evening on the bike. Just wanted to see how bad the battery sag actually is. Here you go:


click on the picture to see full size, its too wide.

Brown=Volts
Green=kmh/speed
Purple=Amps

The graph is so jumpy because I go on fast down a straight, up the hill, turn on the hill, down the hill and so on.

Looks like when I accelerate the batteries sag 20 volts.

Jake

[only1jake]

Been pretty busy lately and haven't been up to much with the bike.

A week ago I stripped it all down to the frame. I am wire brushing the sh** out of it. It's incredibly full of rust, luckily its surface rust only. Then I will be spraying it etc.

I am working on a small RFID system (PICAXE and ID-12) instead of the keyed ignition. So it will be KeyLess Ignition. Just swipe the tag/card and it'll turn on by the flip of the switch. It'll be a unique bike for sure.

I am working on a new site. I have a new website for the blog, well it redirects to the blog; http://blog.gammaelectrix.com The actual website is an online shop I'm working on. You can view it at http://www.gammaelectrix.com (may be under maintenance) It's being worked on and wont be online for sales in a while still.

Also, I've gotta get on to designing or thinking of what I'm gonna do with the fairings and tank etc. Little dash board or something....

Jake

[only1jake]

Photos:
http://www.brightsparks.org.nz/assets/upload/58673/-991290521/Programming%202%20SSR%20%2B%20LED.JPG
http://www.brightsparks.org.nz/assets/upload/58673/1567306615/Kiwi%20Patch%20picaxe.JPG
http://www.brightsparks.org.nz/assets/upload/58673/2004144575/In%20Box.JPG
http://www.brightsparks.org.nz/assets/upload/58673/-429148317/Done%201.JPG

This is the keyless ignition I made for the Electric motorbike. It uses a PICAXE 08M programmed to read the cards ID number and then decide whether this is a correct card or not.

If the correct card or tag is swiped over the reader (ID-12) the 08m sends a signal to the green LED showing that the bike is turned on. If a card that is not programmed into the 08m is swiped, the red LED flashes for 2 seconds, thus telling us that that card will not turn the bike on.

Thanks to the Bright Sparks!!!!

Code is available at: http://www.codeupload.com/755
SAEV Blog: http://tinyurl.com/28j9hev
Suzuki GT50 Conversion: http://tinyurl.com/2fqboqs

Any questions just ask.

[Jay64]

That's pretty cool.

[only1jake]

Batteries arrived, battery mounts nearly done and lots of updates coming very soooooon!

[only1jake]

Batteries Arrived

About a month ago now, they arrived, they finally arrived. With a S*** load of money I had to pay to customs. YEY for sure


Well packaged. Been opened by customs though.

Anyways they are really nice, all very balanced and of very good quality.
The batteries are great, no scratches or damage at all.


attaching the BMS modules, daisy chain.

Balancing and testing all the settings.

BMS is VERY good, very simple yet very complex. Includes individual cell voltages etc on a screen. It also has alarms available and is connected to the charger, so nothing can be over charged etc. BMS also controls charger output depending on cell voltages. Balances it very well and evenly too.


What you get; bms stuff.

Another few updates coming.

[only1jake]

Battery mounts and Paint

I welded the battery mounts and welded them to the frame. Pretty good I say. Well, OK.





I welded the mount for the two bottom ones first, then the two single top ones.



Made sure they were square.



Just making sure they fit!





I then painted the whole frame with a rust converter primer, then with proper sandable primer.





Then I spray painted it Black, 2 layers of black.





PS. If your wondering about the steel. It is Galvanised, that's why it has a funny texture and is a bit thicker. That was the best I could find. Most suitable. Anyway I think it's turned out good.



Another update soon.

[only1jake]

The Mounting Begins

Since I finally reached the milestone and painted the frame and all I could start mounting everything.

Started off by mounting the swingarm and shocks.



I then moved onto the front end and mounted all the painted parts. I also added the mirrors, kill switch, light, horn and indicator switches and the brakes and the throttle.





The awesome electronic speedo and cycle analyst.



I need to fabricate another mount for the rear brake mount because it was a sh**ty.
I put it all together and it looks pretty awesome.







I'm going to be ordering some new steering bearings and a road tyre and tube, maybe a new front rim.

Next things to do is mount all of this gear:



There is; an onboard charger, bms system, all the cabling, connectors, 12v system, dc/dc converter, rfid ignition module, alarm system, controller, contactor, fuse, lights etc and thats about it. Plus making some more mounts for the batteries, to make sure they are firm and dont fall out.




Jake

[maydaverave]

almost there

[bzhwindtalker]

Nice! looking forward to see some ride video!

Adam

[only1jake]

Yeah me too. I just need some time to finish the B*****d off.
Busy with school. This weekend should do.

[only1jake]

Wow it's been a while now.
So so busy with school, now have holidays so lots of building to do.
Here are some pics I took a while ago.







I've also been busy with an electric bike I made with 72v of SLA 7ah. Just for fun really, never had an ebike. It uses a 9c front hubmotor using Lyen's 12FET controller which is awesome. Looking to make a a switchable LIPO pack for this ebike and a custom scooter I am currently building with a 1000w left over motor and a basic brushed setup.

A video here of the motorbike, from testing with the new batteries:



Oh and there has been no further progress on the bike since my last post as the BMS crapped out at the worst possible time, right when I was busy with other things aswell as right before I could do loads on the bike. Anyways, sending it off this week and should be fixed in a few weeks so the bike can be finished. I will be making a thread for the scooter as the build progressed.

And also...

GammaElectrix

now had Livechat available for anyone who needs questions to do with our products. We are also currently working on a forum based for NZ ev'ers and general projects to do with 2 wheeled electric vehicles.
http://www.gammaelectrix.com

Jake.

[only1jake]

So, I sent out the BMS a few weeks ago.
It's been fixed, apparently the screen was the problem.
Will be here in a few weeks.
Then bike can get finished.

Haven't really got much time though; work, another website, gamma electrix and just other stuff.
So Ev's are on the sideline at the moment. But it is summer holiday after all.

Check out the RFID Kits and pre-built units: http://www.gammaelectrix.com/index.php?main_page=index&cPath=11_14
They are **on order** by the way.

[only1jake]

So, turns out I actually had some time on my hands.
Did as much as I could.
I did:
Mounted rear taillight & all indicators
Strapped in batteries and tidied up cables and wiring
Mounted left over loose parts
Road tyre for front wheel and checked brakes
Fitted fixed BMS, which works perfectly now

I drove the bike around for about 7ish KM and used 15% of the battery, till the LVC. Which means I would get around 40km range within the LVC, so 10% remaining.
Don't really know where I would drive for 40km, but that seems like a probable range.

Another thing I noted is the front forks. WAY too much travel and the bike is not straight, ie. front forks too small/need stronger front internal fork springs OR new forks all together, BEST BET.

We are currently working on a forum for NZers to discuss their EVs and organise meetings and stuff. Will let everyone know when we have sorted it out.

Here's a shot:


Just a note that I have bought the polycarbonate for a fairing and the plastic sheet is merely to protect it from NZ weather at testing time

Some Headways just came in, for a downhill style scooter. Thread to come.

[jonescg]

Looking good mate, especially the raincoat

Stay away from those crumbling buildings eh?

[only1jake]

Haha, I didn't even feel a thing where I am. And I am still yet to feel an earthquake

[only1jake]

My first burnout on the electric motorbike!!



Also, if you are an NZ'er make sure you check out http://ev.geek.nz - A forum for NewZealanders to share their projects and discuss electric vehicles and green tech!

[Bluefang]

Hey mate. Great bike looks like a fun little motorbike, Just wondering what sort of range you get on that bike, and a estimate on how much the whole thing weighs as it is currently?

Derek

[only1jake]

I calculated range to be around 50km. Though I haven't run it myself, Need to get it registered first. I think it will go further than that!
As for weight I am unsure. Maybe about 50-80kg. I have no idea. Sorry.

[orpheedulogis]

Hi

Range: 34Ah 48V with this 3kw motor -> about 50km

Something could be interesting: put 72V instead of 48V and look if motor is hot or not. I would be interested to do so but ... would have to change about everything (charger, BMS ...)

[Flip101]

Hi,

I have 32 GBS-LFMP40Ah battery cells and I am currently trying to build a BMS for it. Would you beable to offer any schematic diagrams that could be implemented for such a design? Any information that you would be willing to provide is greatly appreciated.

Thanks