Another scooter to 6kw outrunner conversion

[datahar]

I've Been reading this forum for a long time now, wanted to wait until I had atleast some progress to show before submitting my build.
A little project aimed to run me to and from work, which halfway through the project due to me getting a new job has made the commute <2miles

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The original ped, was bought of a colleague for £50, has been sat in his garden for last 6 years

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First job strip down to frame, remove any surface rust and give it a quick once over with a spraycan

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Step 2 gather all major components, I went for a generic c80-85 for around £60, cheap 150a ESC and an e-throttle

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Step 3 was to cut away all the old ICE parts for the motor to fit inside

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Step 4 was to mount the motor, I spray painted the edges of engine to make a template on some steel sheet, cut it out and this became my mounting point

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After that give the engine a lick of paint and reassemble

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And as the bike stands today:

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My current batteries do not have the amps to be able to power the motor so it's still awhile off its first frankenride, but thats fine gives me chance to either rewire or see what can be salvaged from original loom and get all the panels back on (although I am liking it's current state, it's a rather ugly ped originally )

The project has definitely been a budget orientated one, I don't have the exact numbers to hand but including the bike, spends have been around £250 once the batteries arrive.
One thing I have changed in the project is the choice of batteries, originally I went for li-ion as the individual price is so low, however with the motor's consumption they just were not cutting it, so I have switched now to lipo packs

Another change which I will know once the thing works is to whether I will need to replace the steel plate mount with a thicker gauge.

Overall am very happy and excited to start using my first electric vehicle, let the legal battle begin I suppose...

[Mozart]

Nicely done there datahar, could you say which ECS you've used?

[datahar]

Nicely done there datahar, could you say which ECS you've used?

Thanks. The ESC is simply the cheapest generic 150a Chinese eBay buy

I was right about my mount. It flexed upon first stress test (the ped moved at least)
So I ordered some 5mm steel plate and will get that in over the weekend weather depending)

[flanders]

lookin good keep us updated

[gwhy!]

Hiya datahar,
How have you connected the motor to the splined shaft that fits into the variator ?. It looks a much neater job than how I done it.

[datahar]

Hiya datahar,
How have you connected the motor to the splined shaft that fits into the variator ?. It looks a much neater job than how I done it.

Actually I haven't, I still need to add alittle shim as theres a tiny (<.5mm) difference between the original and new motor shaft,
beacuse I have mounted the outrunner right inside the casing, I have simply slotted the variator etc on and tightened it up, because it gets clamped against the motor housing thats also spinning I didn't see a need in the splines (testing will tell if I am right or not though)

had a play last night, the new steel actually works as a motor mount, and the moped moved! woo
although 2 things I did learn
-in the dark red looks an awful lot like black up until the point theres a huge spark and a smoldering ember land on the battery pack!
-when slowly revving the engine to ensure central alignment, dont over rev until the thing jumps forward off it's sidestand and fall over

over all though, going well, will post a running video and a shot of my variator set up tomorrow when I'm actually infront of the thing in daylight

on other notes, I was contemplating (keeping with the rc theme) a petrol rc engine turning an in/outrunner as an onboard (removeable for tax reasons) but more importantly small form generator
any thought? good? bad? I don't expect to be able to ride whilst it powers the motor, but I could leave it running to recharge with an auto cut off when battery is full, seems a more reliable back up if I ever get caught flat, I have a 1.5w solar panel thats to be stored under the seat as an emergency back up, but solar relies on a resource that's there 50% of the time at best

The battery pack is being designed to be removeable and carries it's own house plug for guarantee of finding a charge, but I'm a cautious soul

[Dauntless]

So much chinese junk lasting 700 miles out there, this is a great project. The rest of the bike should last, it's just the engines that blow up.

[datahar]

Well to drag up an old thread...
I am still awaiting the legal side of this conversion.

The test run I did it was extremely under powered whilst running at 6s3p, but 6s is all my cheapo controller can handle.
Is it possible to use dual ESC or do I need to cough up a 12s capable?

Hoping to get this finished soon so I can get rid of my car and go 100% electric

Then ofcourse I will be wanting to convert a car once it gets too cold

[gwhy!]

Well to drag up an old thread...
I am still awaiting the legal side of this conversion.

The test run I did it was extremely under powered whilst running at 6s3p, but 6s is all my cheapo controller can handle.
Is it possible to use dual ESC or do I need to cough up a 12s capable?

Hoping to get this finished soon so I can get rid of my car and go 100% electric

Then ofcourse I will be wanting to convert a car once it gets too cold

yes you will need a controller that can handle the voltage, I know it may sound like a pain but I think it would be better if you add internal sensors to your motor and use a standard e-bike 12fet controller, this will get you up and running at the voltage that you need with minimum cost, once you are running with that setup then you can think about upgrading the power that the controller can put out.