I've been having to ride this thing with a fixed gear drive to work in order to get the dropouts cleaned up for the dp420 treatment. Rides pretty nice with no electricity! Gotta love that peace of mind of a simple bike
So I decided I really couldn't stand the current panels, especially after I got "removable" silicone sealant stuck on to the panels (I later found very soft, adhesive backed seals much more useful). Originally, I had to cut each panel out of separate 24x24x.118" polycarbonate sheets on a gantry mill. This time, I will just barely fit both panels on one sheet, saving me $25. Once I have them milled out, I will trace the edges on the aluminum, disassemble everything, and cut off all excess aluminum. This will reveal a good portion of the frame, including the surly Logo on the down tube. I hope that it will cut about 5 lbs of nonsense off as well.
Like my molex charge port? It's gonna be a pain in the ass to actually hook up (already got most of it done, but cramming it in SAFELY is my concern). When I have the new panels made, I will insert the molex holder and get an idea of the shape of the internal bosses used for securing the port. I will DP420 them (why not, I''ll have excess from TA extensions). The the whole assembly will bolt on with 1/4" bolts of some type. I'm thinking of working out a magnetic cover/seal for the port (but remember, there will be a plug inserted to enable the bike through middle 4 terminals)
I am going to get one of those long toggle switches and poke it out the top of the enclosure for my precharge circuit (so I don't have to open up the bike to disconnect precharge if I'm going to be away for a while)
THere is an extra pin on the balance connector that I may use for charging the auxiliary 4s1p 18650 battery located in the seat post (wires come out the water bottle boss). Would it be okay to ground the auxiliary pack with main pack? I don't see any real safety hazards.
here is a comparison shot with the huge originals. It's much easier to CNC these panels when you have a functional prototype. reusing 3 of the original holes in the new panels will make alignment and hole tapping a breeze