Nomad - Brat Enduro ASI8000 build

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Apocalypse   10 µW

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Nomad - Brat Enduro ASI8000 build

Post by Apocalypse » May 20 2019 10:07pm

Hey there guys!
Been a lurker for the longest of times, and decided to post a build log of my electric enduro brat build.
Short introduction, i'm from the Philippines and decided to start retrofitting gas bikes to awesome all-electric.
I work with a small team, in a very nitty-gritty compact garage. :D

Nomad
Basebike: Rusi KRZ200 (chinese steel-framed dirt bike.)
Motor: HPM-10K (Golden motor 10kw, watercooled.)
Controller: Asi BAC8000
Batteries: Samsung 25r 20s 35p
Tires: 120/90-18 rear, 90/90-21 front
Sprockets: 12t front, 90t rear
Total system cost: around $6-7k++

Presently set to around 450a battery, 800phase and topping off at 120kph. No real sense to go any faster, given the road and traffic conditions here.
BUILD LOG.jpg
1. Bought the frame around january, roughly around $250 for the entire thing with papers to my name.
1 base bike.jpg
2. Got some mild steel, welded it to the frame for a mock-up mount with my other old and busted gm10kw that blew up from spinning up too fast. :lol:
2a motor mount.jpg
3. Using CAD (Cardboard aided design :P ) a rough mockup of how the batteries are going to be fit. In my bikes case, it had to be three separate modules working as one in order to maximize the space, making all 700 cells fit.
3a battery fitting.jpg
4. As i've said, nitty-gritty lmao. While waiting for the samsung 25r's to arrive, we're using what cells we have to get the overall pack configuration in shape.
3c battery fitting.jpg
5. Cells are finally here.
4a final battery to be used.jpg
6. My battery specialist, Alexander working a blur in our awesome secret laboratory that's totally not a fire hazard of a place. Cells are glued, welded with a k-welder. Nickel strips and copper busbars. Kapton, waterpoofing cloth and then resin painted over it.
4c final battery.jpg
7. The stock bike had horrid 16"/18" wheels, which was much too small for my size. I'm relatively tall for an asian, being 6'0 feet flat. Our local laceman is used to our kooky projects, setting up mxus', qs205 and qs273's with no problem. Spokes are and labor generally don't go above $10 per wheel.
5b wheel lacing.jpg
8. Bike's starting to look proper. Also, if you've noticed i've changed the stock chinesium upside-down suspension to an old yamaha tenere' xtz 660 96' model a good friend of mine sent my way.
6a  new wheel installed.jpg
9. Sprocket is installed, and chained up. This is a local #40 industrial sprocket sold in the dark alleyways of my country. Works great with a 428 chain. Chain guard was later installed.
7a rear sprocket installed.jpg
7b rear sprocket installed.jpg
10. Here the body has been repainted to matte black, and the golden motor 10kw mounted.
10 motor mounted with body painted.jpg
11. Main "Africa" shaped battery module is slid in sideways into the belly, while the two smaller modular packs sit on top of it. The water cooling inlets couldn't be used do to it hitting the pack, so I just filled it with coolant, sealed it, and used forced air cooling later on. Works great.
11a battery installed.jpg
12. Cutting up some stainless sheets of adequate thickness and a little persuasion with a rubber mallet, and the battery guard is made. The skidplate underneath is still a work in progress. :roll:
12a belly guard installed.jpg
13. A friend of mine offered up to re upholster my seat for $30, and I requested a classic brown faux-leather finish, with a darker pattern in the middle for a two-tone look.
13 seat installed.jpg
14. Here's the bike with more paint and accessories fitted. All its 12v systems (lights, horn, keyless alarm) are powered by common 10a pull-down converters. I've got 4 in parallel.
14 painting and finalization.jpg
15. 130w osram led headlight. I love this thing. Nice, clean beam and great brightness.
14a headlight installed.jpg
16. My girlfriend gifted me with a laser cut decal that fits in this nice little spot on the motor. You will ride eternal, shiny and chrome. (also, the little super fans are installed. Don't be fooled by their size! They blow a lot of air, comparable to hotel hair dryers.)
15 motor decal and forced air cooling installed.jpg
17. Body lighting for better visibility, while keeping thematic to my red/black colors.
16 night shot with red body lights.jpg
18. Fast forward a week or so later, I brought the bike to a local flat-track funrace. Nomad is sitting alongside his other e-buddies. Scrambler on the left is a qs 273 tourer build, so is the green bling machine and the desert scrambler peeking on the right.
17 track day, very dirty..jpg
19. Powder. Cough.
17a track day, very dirty.jpg
20. I'd like to thank evolution gts for the asi controller, hence the stickers to represent. Also, you can see the xt90 charging connectors by the side, for easy access.
18 stickers to represent.jpg
21. Alexander on a bafang powered emtb and I on Nomad taking on custom gas bikes in the flat track race.
I won first, he won third on the first round. We both effed up on the finals due to slipping on the same spot, hahaha. :lol: :lol: :lol:
18 vs gassers with a emtb friend.jpg
22. Nomad.
18a vs gassers S.jpg
23. Couple of more beauty shots. :D
extra, bike still clean. no chain guide or motor decal yet..jpg
gabe solo S.jpg
Proud owner S.jpg

And a quick n' short vid of him in action.
Last edited by Apocalypse on May 20 2019 11:02pm, edited 3 times in total.

flat tire   1 MW

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Re: Nomad - Brat Enduro ASI8000 build

Post by flat tire » May 20 2019 10:27pm

DIY Zero FX for pennies on the dollar, nice!

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Apocalypse   10 µW

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Re: Nomad - Brat Enduro ASI8000 build

Post by Apocalypse » May 20 2019 10:29pm

Less than a week ago, managed to procure some CRF 250 08' model forks. Actually, the entire front set. It handles bumps and overall road harshness MUCH BETTER.

Also, a peek as to what kind of road conditions prevail here in the philippines. Slicks ain't gonna cut it here.
STREETS.jpg
STREETS2.jpg

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Apocalypse   10 µW

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Re: Nomad - Brat Enduro ASI8000 build

Post by Apocalypse » May 20 2019 10:30pm

flat tire wrote:
May 20 2019 10:27pm
DIY Zero FX for pennies on the dollar, nice!
Hahaha, i can't afford one, so make one instead! :lol: :lol: :lol:

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liveforphysics   100 GW

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Re: Nomad - Brat Enduro ASI8000 build

Post by liveforphysics » May 20 2019 10:51pm

Bad ass build! Great job!
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Each engine start sprays them into a shared atmosphere which includes beings not offered an opportunity to consent accepting these cancer experiences and defective genetics life experiences.

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Apocalypse   10 µW

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Re: Nomad - Brat Enduro ASI8000 build

Post by Apocalypse » May 20 2019 11:03pm

liveforphysics wrote:
May 20 2019 10:51pm
Bad ass build! Great job!
Thank you!! :shock: :shock: :shock:

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Dui, ni shuo de dui   1 kW

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Re: Nomad - Brat Enduro ASI8000 build

Post by Dui, ni shuo de dui » May 21 2019 2:57am

Amazing build, great pictures, awesome video....
Please post more!
:bolt: :bolt: My electric Ninja 250 clone: 16 000W 72V40Ah A123 cells : :bolt: :bolt:
https://endless-sphere.com/forums/viewt ... 12&t=90032

:bolt: :bolt: My electric Scooter: 11 000W 72V 50Ah LiFePO4 cells: :bolt: :bolt:
https://endless-sphere.com/forums/viewt ... 12&t=75912

AEcustoms   1 µW

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Re: Nomad - Brat Enduro ASI8000 build

Post by AEcustoms » May 21 2019 3:05am

Hey Brother. I promise to have a better battery station. Sooner than you think ;) no more building batteries on a HOLY couch ahahah patched with a GM stator lol

Rube   100 W

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Re: Nomad - Brat Enduro ASI8000 build

Post by Rube » May 21 2019 5:16am

Awesome build, fast and it looks fantastic, and you built it on a pretty tight budget which takes a lot of commitment. Glad you are happy with the result :bolt: :bigthumb: :bolt:

stammerhamlets   1 µW

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Re: Nomad - Brat Enduro ASI8000 build

Post by stammerhamlets » May 21 2019 6:37am

Great build. Now, I want to do this one :D

litespeed   100 kW

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Re: Nomad - Brat Enduro ASI8000 build

Post by litespeed » May 21 2019 8:18am

Excellent build. Love the overlay Watts, volts, KPH blah, blah on the video.

Thanks for sharing.

Tom
I'm married so you know I'm no stranger to pain!

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Apocalypse   10 µW

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Re: Nomad - Brat Enduro ASI8000 build

Post by Apocalypse » May 21 2019 1:09pm

Dui, ni shuo de dui wrote:
May 21 2019 2:57am
Amazing build, great pictures, awesome video....
Please post more!
I'll keep this thread updated as often as I can! :)
Thank you :)
litespeed wrote:
May 21 2019 8:18am
Excellent build. Love the overlay Watts, volts, KPH blah, blah on the video.

Thanks for sharing.

Tom
Thank you Tom! :)
Rube wrote:
May 21 2019 5:16am
Awesome build, fast and it looks fantastic, and you built it on a pretty tight budget which takes a lot of commitment. Glad you are happy with the result :bolt: :bigthumb: :bolt:
Yes, my bike is a invaluable companion in my day-to-day life now.
Just had to make do with the resources around me. :shock:
Thank you! :)
AEcustoms wrote:
May 21 2019 3:05am
Hey Brother. I promise to have a better battery station. Sooner than you think ;) no more building batteries on a HOLY couch ahahah patched with a GM stator lol
Haha, our 5kw couch!! Yeah man, bigger projects to come!

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spinningmagnets   100 GW

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Re: Nomad - Brat Enduro ASI8000 build

Post by spinningmagnets » May 25 2019 6:35pm

I finally found some time to assemble an article.

http://electricmotorcycle.com/gabriels- ... ilippines/

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Apocalypse   10 µW

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Re: Nomad - Brat Enduro ASI8000 build

Post by Apocalypse » May 27 2019 5:58am

spinningmagnets wrote:
May 25 2019 6:35pm
I finally found some time to assemble an article.

http://electricmotorcycle.com/gabriels- ... ilippines/
Hey! Thank you very much for featuring my humble build!! :shock: :shock: :shock:
Much love and gratitude to you, brother! :D

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