Update 3: I really need to update this first post to reflect my project at this point in time. GIST cromotor in too big of a wheel at 4.3kW. Fun. Want to move to 24" wheel with huge tire (26" diameter) to increase efficiency. I'm waiting for some linear boards to transition from balancing with hyperions because it isn't very practical in my design and living situation. I'm also exploring a cooling situation for the motor and am considering reconfiguring my 5p20s pack to 4p25s for more power.
Update 2: the bike is about done with 100 cells of A123 at 20S. My 2807 limits me, but it's been fun for initial testing... But havent tried on 20S yet. Getting everything sealed up well and making new enclosure for 12 fet controller. I have decided to try to get my hands on a greyborg (edit: and by that I mean cromotor....oops...).
update: this thread was originally discussing the panel fabrication, but now that I'm finished with that I wanted to get more into the rest of the build...
9x7 is being laced to a black velocity chukker rim. The rim has angled drillings from the factory (I think), to cut back on some of the sharp angle at the spoke nipple.
panels will get some logo treatment.. possibly LED treatment as well..
21s5p A123 M1 pack. 50A 12 FET. 70-75 lb-ft torque max. 2000W max
I'm not sure I can live with 2000W full throttle at around 20mph... that has been my average speed on 14s5p and I'm geting 12 miles range electric-only.
enclosure is made from 2" aluminum u channel I welded up.. It is removable. Bottom section is one piece which is help in place by water bottle mounts for positioning. Then the top piece of u bolted on the top tube. Lastly, some brackets secure the top corners of the framing, allowing it all to be removed easily.
I am making a triangle pack which is covered with 1/8" polycarbonate panels on each side. I am designing the shape to cut out with a cnc gantry router, but I feel like I need to incorporate some special shapes in... With something more intricate, I'd feel more justified using a $50k machine. For example: a high voltage symbol sticking out underneath down tube. I rather not engrave into the surface of the polycarbonate... rather would like to make "stencils" or modifications to the contour. Any ideas are welcome!
I am working with 24x24" clear panels.. I do not plan to paint the plastic.. Rather I'll just slide in whatever posters or color schemes inside.
I have not finalized the edges or anything in this picture...