E-Ducati Build

Show off your E-Scooter or Motorcycle creation here.
Post Reply
EVbikenoobie   1 mW

1 mW
Posts: 10
Joined: Aug 08 2018 8:06pm

E-Ducati Build

Post by EVbikenoobie » Aug 08 2018 11:30pm

Hi all,
My name is Jon, and here's a bit of background story about the build, and myself.
I'm currently living in Guangzhou, China, where the build will be taking place, and as many know that the censorship here is crazy so "googling" is out of the equation. (VPN works, sometimes, maybe...)
You guys can imagine how agonizing it is to do research without GOOGLE AND YOUTUBE, search engine here is shit, and DIY-EV community is equal to NONE. My only experience with EV/E-bikes is that I've built an E-go kart while back in the states, which is pretty much NEWBIE level comparing to most people here.
So! I will be throwing out lots of amateur questions, PLEASE do help me out!! Thanks in advance!!

Enough with the chipchats and moving on to the build.

ONE MORE THING, it would be GREATLY APPRECIATED IF vendors can ship parts/items internationally... EVpower and most don't... cough cough cough... cough, yeah. Or if you guys can help me out with shipping..

I'm looking to build an AWESOME ONE OF KIND Electric Ducati.

Frame: 2009 Ducati 1098/898
MOTOR: ME1507 (This is actually made in china, I know a guy from factory that makes exporting motors. )
Controller: Sevcon Gen4 Size 6
Battery Pack: LG ICR18650 HG2 (Hopefully these are authentic, cells do hold 3000mAH)
Nominal Voltage: 96.2v
BMS: Not decided, probably only gonna use it for Charging, Discharging will be straight out of the terminals.

GEARING: this is a major problem, I'VE NO IDEA!! and motor sprocket is so difficult to find in china...
I was thinking to make a gear reduction box, but idk how to CAD so...



Should be an interesting build.. and hopefully won't be a dead build thread.
please note that I'm carefree with my language, it maybe explicit.

Image

Image
Last edited by EVbikenoobie on Aug 09 2018 12:03am, edited 1 time in total.

EVbikenoobie   1 mW

1 mW
Posts: 10
Joined: Aug 08 2018 8:06pm

Re: E-Ducati Build

Post by EVbikenoobie » Aug 08 2018 11:41pm

Image

I dunno how to CAD and drawing isn't my thing, so i'm just gonna go ahead and put this "concept" out here.
Yes, it's gonna be a blue frame!!!!

This is pretty much what I've in mind. Right now, I need to build a lower chassis to hold battery packs and Motor.
Will "TRY" to make it an extended chassis to ducati's trellis frame design.
Since it's gonna involve welding, which I've only done less than five times in my life, and pipe notching without notcher.
It may take a minute to finish...
It is very difficult to find a good tig welder, in China.......................
Last edited by EVbikenoobie on Aug 12 2018 10:03pm, edited 2 times in total.

EVbikenoobie   1 mW

1 mW
Posts: 10
Joined: Aug 08 2018 8:06pm

Re: E-Ducati Build

Post by EVbikenoobie » Aug 08 2018 11:41pm

this is also mine

stamen   100 µW

100 µW
Posts: 9
Joined: Oct 13 2014 9:36am

Re: E-Ducati Build

Post by stamen » Aug 09 2018 1:12am

Well I guess our builds have some similarities 8). Good luck I'll be following it.
Instagram @stamen.tintikov

dwcrigler   1 µW

1 µW
Posts: 1
Joined: Jun 07 2017 2:52pm

Re: E-Ducati Build

Post by dwcrigler » Aug 09 2018 7:14pm

I have sprockets to fit the me1507. Search Amp sprockets on Facebook. Also in Electric Motorcycle Builds Exchange - Facebook group

User avatar
Bernel   100 W

100 W
Posts: 148
Joined: Feb 03 2013 3:33pm
Location: Peterborough, England

Re: E-Ducati Build

Post by Bernel » Aug 10 2018 2:02pm

This is also the same as my build, good luck and I hope we can learn off each other.

Bernel

User avatar
Burntspot   10 mW

10 mW
Posts: 26
Joined: Oct 21 2015 8:20am
Location: South East

Re: E-Ducati Build

Post by Burntspot » Aug 12 2018 9:59am

Hi, I just subscribed. I am planning a similar build as I am graduating from e-bikes :D (check my signature). I posted a CAD file of the ME1507 motor recently as I couldn't find one to mock up my bike in Fusion360. I placed a link to it below if it may be of some help to you. I have not started my build thread yet, but I wait in anticipation of your build updates. I am really interested in your battery pack design, if you can share. Cheers

Motenergy ME1507 on GrabCAD: https://grabcad.com/aastan.gadson-1
Last edited by Burntspot on Aug 17 2018 8:16am, edited 2 times in total.

EVbikenoobie   1 mW

1 mW
Posts: 10
Joined: Aug 08 2018 8:06pm

Re: E-Ducati Build

Post by EVbikenoobie » Aug 12 2018 9:32pm

Burntspot wrote:
Aug 12 2018 9:59am
Hi, I just subscribed. I am planning a similar build as I am graduating from e-bikes :D (check my signature). I posted a CAD file of the ME1507 motor recently as I couldn't find one to mock up my bike in Fusion360. I placed a link to it below if it may be of some help to you. I have not started my build thread yet, but I wait in anticipation of your build updates. I am really interested in your battery pack design, if you can share. Cheers

Motenergy ME1507 on GrabCAD: https://grabcad.com/library/motenergy-m ... ic-motor-2
Good to see another ME1507 build!!
Will be packing the batteries right after Motor mount and extended chassis, so i know exactly how much space available to place the batteries. Idk how to cad the entire bike so i've to do the old fashion way, mocking up the actual parts.

btw your CAD link is 404. Maybe it's just my computer....

EVbikenoobie   1 mW

1 mW
Posts: 10
Joined: Aug 08 2018 8:06pm

Re: E-Ducati Build

Post by EVbikenoobie » Aug 12 2018 10:04pm

Finally... my motor sprocket is here...
First custom order is complete shit,
Image

I told them the shaft diameter with 11 teeth, and specifically told them it's pairing with 525 Motorcycle chain!
This is what they sent me... wtf...??

Then, I sent in the rear sprocket and ask them to redo the sprockets with two different teeth number.

Finally send out the correct stuff...
Image

HOWEVER!!! they fked up the keyway, fortunately it's only minor issue, i'm not gonna send it back again...
I'll need to file it down a bit to make it fit on the motor...

Time to custom these is about 2 days process after payment, with 2 days shipping. (shipping is crazy fast in china, and cheap)

total cost for the two correct sized sprocket = 210 rmb (~31 USD) 2 days shipping included.
Made with 304 stainless steel.
Last edited by EVbikenoobie on Aug 13 2018 11:25pm, edited 1 time in total.

EVbikenoobie   1 mW

1 mW
Posts: 10
Joined: Aug 08 2018 8:06pm

Re: E-Ducati Build

Post by EVbikenoobie » Aug 12 2018 10:04pm

and this post

EVbikenoobie   1 mW

1 mW
Posts: 10
Joined: Aug 08 2018 8:06pm

Re: E-Ducati Build

Post by EVbikenoobie » Aug 12 2018 10:05pm

anddd this one as well, reserved.

User avatar
Burntspot   10 mW

10 mW
Posts: 26
Joined: Oct 21 2015 8:20am
Location: South East

Re: E-Ducati Build

Post by Burntspot » Aug 13 2018 7:12am

EVbikenoobie wrote:
Aug 12 2018 9:32pm
Burntspot wrote:
Aug 12 2018 9:59am
Hi, I just subscribed. I am planning a similar build as I am graduating from e-bikes :D (check my signature). I posted a CAD file of the ME1507 motor recently as I couldn't find one to mock up my bike in Fusion360. I placed a link to it below if it may be of some help to you. I have not started my build thread yet, but I wait in anticipation of your build updates. I am really interested in your battery pack design, if you can share. Cheers

Motenergy ME1507 on GrabCAD: https://grabcad.com/library/motenergy-m ... ic-motor-1
Good to see another ME1507 build!!
Will be packing the batteries right after Motor mount and extended chassis, so i know exactly how much space available to place the batteries. Idk how to cad the entire bike so i've to do the old fashion way, mocking up the actual parts.

btw your CAD link is 404. Maybe it's just my computer....
Link repaired

User avatar
macribs   1 GW

1 GW
Posts: 3481
Joined: Jul 22 2014 5:59pm

Re: E-Ducati Build

Post by macribs » Aug 17 2018 7:30am

Subscribed.

User avatar
Burntspot   10 mW

10 mW
Posts: 26
Joined: Oct 21 2015 8:20am
Location: South East

Re: E-Ducati Build

Post by Burntspot » Aug 17 2018 8:14am

I have been working on some more models/CAD files: https://grabcad.com/aastan.gadson-1

stamen   100 µW

100 µW
Posts: 9
Joined: Oct 13 2014 9:36am

Re: E-Ducati Build

Post by stamen » Aug 18 2018 3:44am

Burntspot wrote:
Aug 17 2018 8:14am
I have been working on some more models/CAD files: https://grabcad.com/aastan.gadson-1
Thanks for uploading these! Do you know if the ME motor casing has the same overall dimensions and bolt hole pattern as the ZF 75-7 motor?
Instagram @stamen.tintikov

User avatar
Burntspot   10 mW

10 mW
Posts: 26
Joined: Oct 21 2015 8:20am
Location: South East

Re: E-Ducati Build

Post by Burntspot » Aug 18 2018 9:47am

stamen wrote:
Aug 18 2018 3:44am
Burntspot wrote:
Aug 17 2018 8:14am
I have been working on some more models/CAD files: https://grabcad.com/aastan.gadson-1
Thanks for uploading these! Do you know if the ME motor casing has the same overall dimensions and bolt hole pattern as the ZF 75-7 motor?
From my understanding they are the exact same motor minus some minor tweaks in performance between Me1507, 75-5 and 75-7

EVbikenoobie   1 mW

1 mW
Posts: 10
Joined: Aug 08 2018 8:06pm

Re: E-Ducati Build

Post by EVbikenoobie » Oct 18 2018 8:52am

Late late updates due to busy busy days.
Let the work keep on going!!
First thing first, I've got a new 1098 frame because the red one was damaged at the steering bearing. Unable to seat a new bearing.

Image

Then move on to the motor mount, his Motor mount is made out of 6061 aluminium. Cost about ~ $50 plus same day shipping, though it took a week to CNC.

Not really a perfect fit due to some design flaws, had to grind some spots but overall, it's a great fit.


Image

Image

User avatar
macribs   1 GW

1 GW
Posts: 3481
Joined: Jul 22 2014 5:59pm

Re: E-Ducati Build

Post by macribs » Oct 18 2018 9:55am

I read in your first post that you will weld the battery box to the frame. I am thinking that you would not need to weld it to the frame. Just make custom clamps that clamps the batterybox onto the frame. The trellis frame is plenty strong for you to hang the battery box onto the frame. That way you dont need to risk bad welds, or worst even warping of the frame. Maybe the frame has some mounting points where the battery case can be bolted to the frame? Then battery box should act as a stress member and give more overall strength.

Regarding jack shaft or reduction gear box, what wheel size will you be using in the rear? And what size of sprockets can you get locally? That motor you got has a rotor max speed of about 6000 rpm iirc. Maybe with a 16" wheel you will not need any more reduction then what you can via the sprockets?

EVbikenoobie   1 mW

1 mW
Posts: 10
Joined: Aug 08 2018 8:06pm

Re: E-Ducati Build

Post by EVbikenoobie » Nov 25 2018 12:54am

Continuing with the build
This time i'm working on the battery and sevcon wiring.
just to put everything into actions.


battery pack consist of two modules, each at 48v nominal.
Each module's with figuration of 13s22p, using LG HG2 18650 cells.
Total gives 96V 66Ah
LG HG2 can draw 20A each cell, so the goal or the max amp is at 440A.

Will not be using BMS, until i find one.....
Battery Charger has a voltage protection itself so charging to full is not a problem. (Fully charged at 109v.)

Image



and the wiring for sevcon I'm using a sheet off EMF-power, if there's any different way to wire, please let me know.
I'm missing the wiring for display output (rpm, temp, etc)

and ofcourse, REGEN.
PLEASE!! IF THERE'S ANYONE OUT THERE!!
PLEASE , help me with regen, i'd like to have a "left hand" type of regen.
Thank you!!

Image

Image

annnnnnd then we'll see how this goes.

TilmanBaumann   10 W

10 W
Posts: 86
Joined: Feb 15 2018 10:32am

Re: E-Ducati Build

Post by TilmanBaumann » Nov 26 2018 1:54pm

Looking fantastic.

Unfortunately, at those types of currents, all cheap Chinese BMS fly out of the window. :(
Personally I love OrionBMS. Great software, great documentation lots of features.
But at that kind of price range, you have other options too.

Maybe a cheap Chinese BMS but instead of driving the real load, only let it drive the DC/DC and through that a high current contactor for the motor driver.
That way you lose current sense from the BMS. But at least you allow the BMS to cut off the load if it needs to. Should work, although I never tested it.

User avatar
fechter   100 GW

100 GW
Posts: 12907
Joined: Dec 31 2006 3:23pm
Location: California Bay Area, USA

Re: E-Ducati Build

Post by fechter » Nov 26 2018 3:15pm

TilmanBaumann wrote:
Nov 26 2018 1:54pm
Looking fantastic.

Maybe a cheap Chinese BMS but instead of driving the real load, only let it drive the DC/DC and through that a high current contactor for the motor driver.
That way you lose current sense from the BMS. But at least you allow the BMS to cut off the load if it needs to. Should work, although I never tested it.
That would work for protecting the pack during discharge. For charging, it may take a little interface circuit to run the contactor. If the charging current is low enough, the BMS might be able to handle it.
"One test is worth a thousand opinions"

Post Reply