Electric Race Bike

[Jay64]

Yep, I'll definitely be posting up as many vids and pics as possible. I'm hoping that it goes good enough to compete against some gas bikes at JenningsGP for some club races. They have an "unlimited" class that allows unlimited modifications, so technically this bike will be legal. So hopefully I'll have some results from the US TTXGP and from the gas races too.

[voicecoils]

Nice lipo stash! Which packs did you end up with?

[edit] just re-read the thread, "ZIPPY Flightmax 5000mAh 5S1P 20c packs. 72 packs in 9s8p configuration for 166.5v40ah"

Here's the bussbars Jozzer makes:

From http://Www.jozztek.com

They will simplify connections tremendously, just plug straight in.

Yes, the soliton jr will take a Magura pot throttle. Make sure to set some motor current limits in the controller straight away or it will fry Agni's at 600A!

[Nuts&Volts]

Very nice. Does the liquid have a very potent smell? It would seem you have a cell leaking electrolyte. This can happen with a cell that still shows normally open circuit voltage (first hand experience). I would guess thou that that cell would not be able to handle the high discharge rates any longer thou.

Good luck with the build. I am hoping to make it out to the Laguna race to see and meet all the El Moto racers I can. Also let me know if you decide to go the cell-log route, I work with a team that is making a pretty simple circuit to use them as HVC and LVC

[jonescg]

Far Canal Jay! It normally take HK about 6 weeks to get me stuff! At this rate I have no doubts you will be ready in time. Oh, and make sure your Technical Control File is up to date. They let us Aussies get away with more dumb stuff cause no-one was looking... But they are probably taking it a bit more seriously in North America.

I'm keen to see what you come up with for the motor mounts and battery tray, cause I could probably make use of the same shape for my 2013 bike. Except my motor will be sitting inside the mount, not out either side

Looking good mate!

[Jay64]

From http://Www.jozztek.com

Thanks for the info. How are those connections connected to the bus bar? Are they soldered in place?

N&V I didn't notice a smell, but I didn't actually smell it specifically and I promptly wiped it off, so that I wouldn't get it all over the carpet I was working on. (Already got yelled at for getting grease on the last one while doing a build in the living room. ) If you make it out to Laguna, definitely stop by and say Hi. I'm definitely open to the cell log route. I just need it to cover the rules requirements. And cheaper will be better at this point since I have spent over $5k this week on this bike and I have a gas race in Atlanta between now and the gas/electric race in Sears Point. But I don't have any specific one I've found yet.

Chris, I was so surprised when they showed up as well. I guess it helps that they were already in the US so it didn't have to pass through customs and stuff. Yeah, they just sent me the TCF paperwork yesterday. They have been working with me to help me to get the bike ready and up to snuff. I will be more than happy to share what I come up with. I might need to get some specs from what you built.

[voicecoils]

Yes, a hole is drilled into the bussbar and then the bullets get soldered into place. You can heat the bussbar & bullet, fill the bussbar with melted solder and then press the bullet into place.

[Jay64]

Cool, thanks.

[Jozzer]

Don't heat the connectors directly, especially the males - the springs turn brittle very easily and spoil the connection. Keep the flame directed at the bar at all times..

The Soliton comes with several settable limits - you can set the current to 400A (to start with) and limit "total KW" so that only 250A can be supplied at max RPM. Also possible, is an independant battery current limit, which again, will allow high motor current at low speed but limit it as RPM increases. A little experimentation should get you too the settings that allow max power without risk of overheating motor or brushes.

Jozz

[Jay64]

Thanks Steve, I actually just ordered up the soliton jr yesterday.

[Jay64]

I brought the '06 GSXR 600 SuperSport race bike home last night. Got some pics with it still in the van.

[Jay64]

A *mostly* stripped frame.

[Jay64]

The motor, the arrows are the upper motor mounts.

[Jay64]

The measurement from the center of the steering stem tube to the back of the motor cavity of the frame.

[Jay64]

If both of the AngiMotors are going to be sticking out on either side, that is going to have to be one long shaft connecting them.

[jonescg]

You can move the motors further forwards, and tuck them inside the frame a little. My motors are only about 190 mm apart if I recall... The diameter of the Agni is only 250 mm, so you won't have any problems with the drive sprocket being too far forwards.
viewtopic.php?f=10&t=12480&start=315

[Jay64]

Don't the motors have to be out in the wind? Also, didn't you use a different frame then the one I'm using? Not sure if the spacing will be the same.

[jonescg]

The motors will pull air from the endplates and spit it out radially. So it's not going to help them much by being right out in the breeze, except mean you need even bigger crashbars around them, potentially affecting your ground clearance at lean. It also means your toes won't be touching the motor

The spacing will be different for sure, but it's not going to matter much. I would recommend the motor shaft be kept as short as practical though.

[Jay64]

So just the end plate needs to be out in the wind? I was playing around with some crude mock ups on Sketchup I did, and it seems like if I am going to have the shaft line up with the chain, the motor needs to be sticking out rather far on the one side.

I just turned down the deal to race a Lightning motorcycle today. So now I really need to get this bike built in time for the first race.

[sflorlando]

This is a great thread. Cant wait to see what you end up with.

Makes my moped build look very silly indeed!

[Jay64]

The Soliton controller just showed up today. Damn, this thing is HUGE. Glad I went for the JR and not the full sized.

http://evnetics.com/products.php?prod=jr

[Jay64]

This is a great thread. Cant wait to see what you end up with.

Makes my moped build look very silly indeed!

I don't know, I think all EV builds are great. I would like to get the chance to see your moped one day.

[sflorlando]

You just might...I was in your area this past weekend doing the solar thing. And by solar I mean soaking up some rays laying on the beach!

That controller is huge. Specs are quite impressive though. Someday I will do a full motorcycle conversion.

Ken

[Jay64]

Ken, I go up to Orlando quite a bit. Maybe we'll meet up one of these times.

[sflorlando]

definitely! The only ebike I have ever seen was my own, would be cool to pass ideas by you and nerd it out a bit.

[Jay64]

Ok, This is a very crude attempt at mocking up in sketchup. I believe this model is actually a GSXR 1000 frame, it definitely isn't exactly a 600 frame. But it was the closest thing I could find to get the general layout. My crude model of Dual AgniMotor 95R motors, and zippy flight max cells. I actually got lazy and both packs are the same size, even though one should be 4s instead of double 5s. But I figured it would be better to make sure there was room for a larger than needed pack than to go for a smaller than needed pack.