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ATV conversion (mostly done)

Posted: Jan 03, 2018 11:42 am
by romelec

I started to work on my ATV conversion about 4 years ago (with a lot of long pauses), finally last week I could do the first test:

The ATV is a Jianshe 250 bought about 10 years ago for 2000€

Motor: used ME1114 with regular hall sensor instead of the sin/cos, with a pulley and universal joint to the original transmission shaft
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Controller: Sevcon gen 4 size 4 on ebay, with the old IXXAT interface (I don't sell it !)
Motenergy provided me a configuration file they use on a test bench, it was certainly not easy to make it working but I didn't had to modify the difficult settings such as the PI control loop parameters.

Batteries: 10Ah headway cells to form a 72V 60Ah pack
I have also 4 headway cells for the accessory battery and a 12v converter
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BMS: the last model from foundingpower bought before they stopped
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Throttle: I used a thumb throttle modified with 3d printed parts to use a cable so I can keep the original thumb throttle
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Everything fits very very tightly:
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_DSCN3417.JPG (107.25 KiB) Viewed 1083 times

Re: ATV conversion (mostly done)

Posted: Jan 03, 2018 11:48 am
by romelec
The things to finish are mostly around the Sevcon programming:
- figure out how to have regen on throttle release
- add a brake lever for variable regen, I will use an hydraulic one with a pressure sensor
- eventually setup the 3 different profiles with different power / regen levels
- find how to link the BMS to the Sevcon

Re: ATV conversion (mostly done)

Posted: Jan 03, 2018 12:38 pm
by skeetab5780
Awesome build sub’d

Always wanted a two wheel drive sports quad conversion myself, all time favorite quad is 1987 trx250x

Re: ATV conversion (mostly done)

Posted: Jan 03, 2018 2:27 pm
by fechter
Wow, looks like it runs great. Nice work.

Re: ATV conversion (mostly done)

Posted: Jan 03, 2018 5:51 pm
by Hillhater
Very nice conversion.
I just hope you dont regret using those Headway cells,...they do not have the best of reputations.

Re: ATV conversion (mostly done)

Posted: Jan 03, 2018 11:03 pm
by jonescg
Very tidy build!

The Headways will be fine in summer, but they will sag pretty bad in winter.

How far do you think you will get on a charge?

Re: ATV conversion (mostly done)

Posted: Jan 04, 2018 4:10 am
by romelec
Thanks !

Yes I expected that for LiFePO4, but it's fine I won't use it a lot and almost never in winter because I will also be cold !

I have no idea for the range but 50km would be nice to have, I expect it to vary a lot depending on the terrain.

Re: ATV conversion (mostly done)

Posted: Jan 05, 2018 1:40 am
by amberwolf
For winter you could add battery heaters, like the ones used on car-battery lead-acid stuff for more northerly areas. Or those under-tank reptile habitat heaters, like ZooMed makes--they're thin and flat and could be installed inside the battery compartment, then their cords connected together to a single 115vac plug. Leave them plugged in when you're charging, anytime you're not riding but might need to use it, and it'll be warm and ready to go without sag during the ride.

If the battery box is insulated on the outside, it'll keep the heat in, and should last thru it's whole capacity.

Re: ATV conversion (mostly done)

Posted: Jan 05, 2018 9:00 am
by E-Chopper
Great Job !!!
nice pictures !!!

Do you want to register it for street legal use or only offroad !?

Greetings from Austria to France

Re: ATV conversion (mostly done)

Posted: Jan 05, 2018 12:42 pm
by romelec
I wanted to add a heater, there is some insulation in the box (4mm cork) but I have found these tapes only in USA but the shipping to Europe is pretty expensive, about $50 :?
How much power is needed ?

Unfortunately it is impossible (or very expensive) to register converted vehicles in France, so I will keep it like that.

Re: ATV conversion (mostly done)

Posted: Jan 06, 2018 2:14 am
by minimum
Look for 3D printer parts stores - some bed heaters for printers are paper thin.
12 VDC version are most common, 24VDC less common and 240VAC are rare. They come with thermistor attached and should have some kind of additional regulation or it will cook your battery. ... ble-heater

Re: ATV conversion (mostly done)

Posted: Jan 10, 2018 9:20 pm
by GeriatricGeoffrey
looks fun!

cost so far?

Re: ATV conversion (mostly done)

Posted: Jun 08, 2018 10:36 am
by romelec
Sorry for the very very late answer, it costed about 4000€

It is now almost finished, I still have to tweak the controller to have more power at startup but that's all.
Maybe create different drive profiles as I have a switch wired but is is not really necessary.

The issue I had with the regen not working was because I didn't had a FS1 switch on the throttle, when I added it worked immediately.
For the variable regen I didn't use a brake lever but reused the choke lever used with the left thumb.

I plan to make a video presenting everything but don't know when I will have the time, maybe in July.