YZF600R Thundercat EV

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YZF600R Thundercat EV

Postby Bernel » Sun Feb 03, 2013 4:01 pm

Hi all, new to this forum stuff, I took the plunge to convert my 1999 Thundercat to all electric when I lost second gear. I started the process in March 2012, lost of web research. I thought I was being innovative until I realised ev conversions had been going on for years. Any how here are my specifications.

ME0913
KHB72601
Kelly DC/DC converter
72V10A Charger
LiPo Pack 20S7P 74V 70Ah
Last edited by Bernel on Sun Jan 15, 2017 1:42 pm, edited 2 times in total. View post history.
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Re: Thundercat EV

Postby Jay64 » Tue Feb 05, 2013 12:33 pm

Sounds like a cool build. Where are you located? We didn't really call them Thundercats too much in the US. For those who are not familiar, this is the ZYF600R. This bike was the upgrade from the FZR and led to the R6. How far along are you on your build? Post some pics, we are looking forward to seeing this build.
Johnson64.Com "The stone age didn't end because we ran out of stones."
EV Bikes:
'13 Zero S 11.4kwh.
GS500, ME0913, Sevcon Size 6 Controller, 90v40ah Lipo, GSXR suspension..
'87 Hurricane 600, ME0709, 48v/50a SLA, Kelly KD72400, Magura Throttle, High Current Cycle Analyst.
http://www.evalbum.com/2275
Raleigh beach cruiser: 9C rear hub, stock controller, 48v10ah lithium, Cycle Analyst.
Phat Chopper: 9C front hub, stock controller, 48v12ah a123s, Cycle Analyst.
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Re: Thundercat EV

Postby Bernel » Tue Feb 05, 2013 8:19 pm

Hi Jay64, I am in the UK we are a fair bit behind with diy ev's. I will post some pics of my progress soon. My current status is 12V wiring complete, took delivery of my charger yesterday and waiting for my battery box to be fabricated. I did a lot of mock Ups with foam and cardboard. So a few more slabs of aluminium and some welding and I should be good to go.

Will keep you posted, no pun intended.
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Re: Thundercat EV

Postby Jay64 » Tue Feb 05, 2013 9:33 pm

We've had a few brilliant builds come our way from the UK. Looking forward to what you come up with. You should try to meet up with Jeremy Harris and Jozzer to see what they have come up with. Two really great guys.
Johnson64.Com "The stone age didn't end because we ran out of stones."
EV Bikes:
'13 Zero S 11.4kwh.
GS500, ME0913, Sevcon Size 6 Controller, 90v40ah Lipo, GSXR suspension..
'87 Hurricane 600, ME0709, 48v/50a SLA, Kelly KD72400, Magura Throttle, High Current Cycle Analyst.
http://www.evalbum.com/2275
Raleigh beach cruiser: 9C rear hub, stock controller, 48v10ah lithium, Cycle Analyst.
Phat Chopper: 9C front hub, stock controller, 48v12ah a123s, Cycle Analyst.
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Re: Thundercat EV

Postby Bernel » Fri Feb 08, 2013 10:57 am

Hi Jay64,
I bought a charger off Jozzer's website and saw his video on Youtube I think, seems like a good guy. Don't know who Jeremy Harris is though?
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Re: Thundercat EV

Postby Jay64 » Fri Feb 08, 2013 11:18 am

Yeah, Steve (Jozzer) is a real good guy. Both of them are members here on this forum. You can search out some of their stuff by their user name in the author part of the search function.
Johnson64.Com "The stone age didn't end because we ran out of stones."
EV Bikes:
'13 Zero S 11.4kwh.
GS500, ME0913, Sevcon Size 6 Controller, 90v40ah Lipo, GSXR suspension..
'87 Hurricane 600, ME0709, 48v/50a SLA, Kelly KD72400, Magura Throttle, High Current Cycle Analyst.
http://www.evalbum.com/2275
Raleigh beach cruiser: 9C rear hub, stock controller, 48v10ah lithium, Cycle Analyst.
Phat Chopper: 9C front hub, stock controller, 48v12ah a123s, Cycle Analyst.
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Re: Thundercat EV

Postby jonescg » Fri Feb 08, 2013 10:13 pm

Don't worry, we called them Thundercats in Australia too. A very nice bike to ride actually.
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Re: Thundercat EV

Postby John in CR » Sat Feb 09, 2013 9:57 am

Do you already have your batteries? With a pack that size consisting of cells of a chemistry where an issue with 1 cell can cause a thermal runaway of the entire pack in less than a minute, be sure you understand the precautions required. It boils down to making sure no faulty cells make it into the pack, and make sure each cell can neither be discharged to too low a voltage or charged to too high a voltage, and they will serve you well.

Can't wait to see pics.

John
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Re: Thundercat EV

Postby Bernel » Thu Feb 14, 2013 3:00 pm

Thanks all for the responses, I though I would post some pictures of what I have done so far.
yzf26.jpg
Battery mock up
yzf26.jpg (52.66 KiB) Viewed 6745 times
yzf22.jpg
Controller layout
yzf22.jpg (48.58 KiB) Viewed 6745 times
yzf21.jpg
Motor mount
yzf21.jpg (41.92 KiB) Viewed 6745 times


It's amazing what you can achieve with some cardboard and MDF, CAD takes too long for me. I am waiting for the battery box to be fabricated once that is done I will get it welded to the frame and build on top. I have ordered some auminium sheet and plate to replace the MDF once I am happy with where everything is going go.

I was looking at making my own charging point or EVSE as it is called in the UK, turns out in East Anglia you can get one installed for free, all they want in return is the ability to capture data of usage.

I will keep you posted on further events.
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 10:27 am

I though I would show my build history to date, here go's.

11/03/12
My Thundercat lost 2nd gear so decided to do an EV conversion. Here are some picures of the naked bike.
Attachments
yzf1.jpg
Naked from the right
yzf1.jpg (109.06 KiB) Viewed 6691 times
yzf2.jpg
Naked from the right
yzf2.jpg (100.92 KiB) Viewed 6691 times
yzf5.jpg
Engine removed, what a mess!
yzf5.jpg (91.82 KiB) Viewed 6691 times
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 10:32 am

From various forums and websites I worked out how I was going to mount the motor.
Attachments
yzf9.jpg
Motor mounting template made of MDF
yzf9.jpg (76.38 KiB) Viewed 6681 times
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 10:47 am

I was initially going to use GBS batteries and decided to go for 6 x 100Ah, this would give me 72V and plenty of range. I bought some foam cut to the dimensions of the batteries, controller, dc/dc converter and charger that I was going to use.
Attachments
yzf9_1.jpg
Mock up with foam
yzf9_1.jpg (12.41 KiB) Viewed 6678 times
yzf9_2.jpg
With fairing on
yzf9_2.jpg (10.79 KiB) Viewed 6678 times
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 10:52 am

The GBS 100Ah batteries were too big, I wanted to be able to fit the fairing back on to have the bike looking stock.

I ordered some more foam to the dimensions of the 60Ah batteries, these fit perfectly.
Attachments
yzf9_3.jpg
Front view
yzf9_3.jpg (12.94 KiB) Viewed 6677 times
yzf9_4.jpg
Side view with proposed bracing drawn on
yzf9_4.jpg (13.37 KiB) Viewed 6677 times
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 10:56 am

Now that I had batteries that would fit I set about making mock up trays. I ordered some kraft board as mock up angle. It was so easy to work with cardboard and you can actually see how it all fits. This was my final design with these batteries.
Attachments
yzf10.jpg
Bottom tray
yzf10.jpg (24.52 KiB) Viewed 6677 times
yzf11.jpg
Bottom tray with 2 batteries
yzf11.jpg (20.54 KiB) Viewed 6677 times
yzf12.jpg
middle tray
yzf12.jpg (23.97 KiB) Viewed 6677 times
yzf13.jpg
Middle tray with 3 batteries
yzf13.jpg (22.46 KiB) Viewed 6677 times
yzf14.jpg
Top tray
yzf14.jpg (23.04 KiB) Viewed 6677 times
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 10:58 am

This was the way the batteries would have been fitted in sequence but after all that effort mocking it up the cost to import them to the UK was way too expensive.
Attachments
yzf15.jpg
Top tray with single battery
yzf15.jpg (20.42 KiB) Viewed 6677 times
yzf16.jpg
Battery pack finished
yzf16.jpg (23.46 KiB) Viewed 6677 times
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 11:00 am

We are now 25th of August 2012, my ME0913 has arrived, what a beast of a motor, here it is next to the engine.
Attachments
yzf17.jpg
Big difference in size
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 11:03 am

With the motor in my possession I set about designing the mounting bracket. I used MDF and dimensions from the drawing to measure it all out. My skill with a protractor and Pythagoras helped a lot here.

Here was the initial design.
Attachments
yzf18.jpg
Fits like a glove.
yzf18.jpg (57.21 KiB) Viewed 6639 times
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 11:08 am

I was going to use 6mm aluminium for this mount and when I tested the motor by hand with the chain I noticed a lateral twisting force. Then I remembered Elgixer made some C plates for his AC20. I set about designing my own out of MDF again but it will be 12mm aluminium to take the clamping bolts.

My brother got a company to make the motor mounts for me. The front face plates arrived first and it fitted like a glove.
Attachments
yzf20.jpg
Motor mount
yzf20.jpg (51.26 KiB) Viewed 6697 times
yzf21.jpg
Fitted to the bike, sweet!
yzf21.jpg (41.92 KiB) Viewed 6697 times
Last edited by Bernel on Wed Feb 20, 2013 6:36 pm, edited 1 time in total. View post history.
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 11:12 am

We are now 16th December 2012, I have the motor mounted, I have the controller, contactors, emergency disconnect, throttle pot box and various connectors. I cut out some 6mm MDF to mount the controller, throttle and contactors and placed them inside the frame.
Attachments
yzf22.jpg
Controller mounting
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 11:15 am

Next I began working out how I was going to connect the throttle cable to the pot box. I decided against the Magura twist grip as I did not want to mess around with the right hand handle bar. I put pencil to paper and came up with a simple design.
Attachments
yzf23.jpg
Design sketch
yzf23.jpg (39.9 KiB) Viewed 6694 times
yzf24.jpg
Mocked up bracket out of MDF
yzf24.jpg (46.59 KiB) Viewed 6694 times
yzf25.jpg
Throttle cable connected
yzf25.jpg (51.43 KiB) Viewed 6694 times
Last edited by Bernel on Wed Feb 20, 2013 6:38 pm, edited 1 time in total. View post history.
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Re: Thundercat EV

Postby Bernel » Sun Feb 17, 2013 11:17 am

The MDF plate and throttle bracket will be made from aluminium. I shot a video of the throttle in action and I will post it once I have worked out how to do it.
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Re: Thundercat EV

Postby Jay64 » Wed Feb 20, 2013 11:31 am

Looks very similar to one of my builds. Unfortunately I used a sevcon controller and the company I bought it from couldn't program it correctly. Regret not going with a Kelly.
Johnson64.Com "The stone age didn't end because we ran out of stones."
EV Bikes:
'13 Zero S 11.4kwh.
GS500, ME0913, Sevcon Size 6 Controller, 90v40ah Lipo, GSXR suspension..
'87 Hurricane 600, ME0709, 48v/50a SLA, Kelly KD72400, Magura Throttle, High Current Cycle Analyst.
http://www.evalbum.com/2275
Raleigh beach cruiser: 9C rear hub, stock controller, 48v10ah lithium, Cycle Analyst.
Phat Chopper: 9C front hub, stock controller, 48v12ah a123s, Cycle Analyst.
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Re: Thundercat EV

Postby Bernel » Wed Feb 20, 2013 6:16 pm

Hey Jay64,
And there was me thinking I was doing something original;-). It is interesting how things come together I started my design with no external input and when I discovered the EV Universe all the questions and queries I had were already answered.

Any way my aluminium plate arrived today and I have designed my own bus bars. Still waiting on the battery box though.

I would be interested in seeing your similar build, have you got a link to it?
Last edited by Bernel on Wed Feb 20, 2013 6:40 pm, edited 1 time in total. View post history.
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Re: Thundercat EV

Postby Jay64 » Wed Feb 20, 2013 6:36 pm

Well, I used a different chassis. But here is my build thread.

viewtopic.php?f=10&t=38221

It started off with a totally different design idea, and then ended up becoming closer to your build.
Johnson64.Com "The stone age didn't end because we ran out of stones."
EV Bikes:
'13 Zero S 11.4kwh.
GS500, ME0913, Sevcon Size 6 Controller, 90v40ah Lipo, GSXR suspension..
'87 Hurricane 600, ME0709, 48v/50a SLA, Kelly KD72400, Magura Throttle, High Current Cycle Analyst.
http://www.evalbum.com/2275
Raleigh beach cruiser: 9C rear hub, stock controller, 48v10ah lithium, Cycle Analyst.
Phat Chopper: 9C front hub, stock controller, 48v12ah a123s, Cycle Analyst.
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Re: Thundercat EV

Postby Bernel » Mon Feb 25, 2013 1:29 pm

I have given up on the video of the throttle cable in action, I am sure I will work it out later.

So back to the build, 24th December 2012 I set about mocking up the new battery tray which will house the LiPo batteries.
Attachments
yzf27.jpg
Mocked up with cardboard
yzf27.jpg (43.13 KiB) Viewed 6553 times
yzf31.jpg
In situ
yzf31.jpg (64.75 KiB) Viewed 6553 times
yzf32.jpg
Revised mounting arm to frame
yzf32.jpg (40.27 KiB) Viewed 6553 times
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