Looks like your photobucket account is not working.
BTW...for images you need everything inside the quotes "{img]Direct URL Here[/img]" to display pictures. I think you picked the IMG URL instead.
Colorado, not Cali, but since you are in the UK...close enough.
Wiring isn't overly hard. Just assume that you are going to make your scooter inoperative for a while until you get it rewired.
You want to get some high temp wire, pretty much anything 26 awg from Beldin will do fine. You will want at least 10 conductors and realistically more. Assuming you do what I do, that's 3 for throttle, 4 for watt meter, 3 for directionals, 1 for horn, 1 for head lights, brake lights, 2 or 3 more for other lights. So that's 15 conductors or so up to the handlebars. Ground and +12v will be common amonst everything so it's best to have a couple of those in the harness. A lot of Belden wire comes with an outer shield. I use that for my ground wire since it has a 26 awg wire in it usually. I think you wanted to be able to disable the controller from the brake levers. I think you also want brake lights. These 2 things can't run from the same switch at the lever so you will want to get a second set of switches and mount them to your brake levers. The switches are super cheap and readily available on ebay. I just don't bother with controller disable and as a result I need the switches for brake lights only. Anyway, that's another wire for the disable. Most things need either ground or +12 volts. Since the brake lights need 12 volts to turn them on and the controller disable needs to pull that signal to ground, you can't have both on the same switch. If you can find those brake lever switches in dual pole, well that would effectively put 2 switches inside the same switch shell.
I can show you what kinds of lights I think are decent and what's crap. Assume your factory lights won't be reused since they are set up for 48 volts and are probably not very bright. They can be modded for 12 volts if you want to reuse them, but there's better options.
It's just an opinion of mine and you can ignore it if you like. I want to be visible. My scooter is small and fast...far faster than it looks and certainly much faster than it was coming off the factory floor! as a result, I want people to see when I'm changing lanes, see me slow down, have good sight of me because I'm lit up like a Christmas tree. LED's are the answer here. Ever get creamed by a car when you are on a bike doing 30mph? It hurts a lot! I want to avoid those sorts of things if at all possible so lights help a lot. My blue scooter has about 6000 miles on it. Lights have saved me quite a few times! As a result, I have a couple of sets of side lights, front, rear and side directionals, brake lights, tail and head lights and a 110db horn. I'm haulling ass on a very small, fast and nearly silent machine. I'm much faster than bikes...so will you! Make yourself stand out.
Just assume you are getting a DC-DC converter and buy it now. I can show you how to hook it up later.
This is another safety thing...throttles. I didn't notice which you have half twist or full grip twist. Both are fine for a sit down machine, but for standup they are not ideal and they require that your right hand is twisting while you are holding on. The only thing that keeps you on the EV are your feet and hands. Make those things as secure as possible. Use a thumb throttle instead.
Another safety thing...I really didn't pay attention to your deck. If it's plastic, make a new one out of plywood and then cover the top with grip tape. My deck was plastic and a little bit of water or some mud and your feet slide around. Grip tape keeps your feet securely plated. I take 90 degree turns leaned over at 40-45 degrees and I just stay planted on the scooter.
Watch this video of me on my blue scooter...there's some solid 45ers in there. This was on the old 2kw BOMA and before I switched to 219 so the chain is fairly noisy. Same for the brakes. They hadn't been upgraded yet. It still got up and went. I think when that white truck passed me I was doing 35. going past that lake on the left I'm doing 45ish. Are you supposed to go 25 through neighborhoods? I forget? ;P Most of the time I'm doing 30-35mph with a few bursts faster.
https://www.youtube.com/watch?v=wjlvqCRE73c&list=PLP5ztAvpP73YOFCiuzRm1DAUWoxep2mrR&index=9
I found a video I forgot about on my blue scooter build. It's not exactly like this anymore. I did eventually get the chain tensioner moved to the return side.
https://www.youtube.com/watch?v=RdC119Nn_WU&index=10&list=PLP5ztAvpP73YOFCiuzRm1DAUWoxep2mrR
controller mods...go look here. There's pics of a 12 fet in there I modded. That's not exactly like the controller I have for you, but pretty darn close. I eventually blew up that controller doing very stupid things to it. It happens!
https://endless-sphere.com/forums/viewtopic.php?f=4&t=90536
The BMS I typically use comes in 16S or 20S and it won't work on odd cell counts, so you will want to use those cell counts. There's BMS that will do odd cell counts, but honestly just build around 20S and count yourself lucky. I never do odd cell counts. If it's not in 4S increments (12, 16, 20, 24 and so on), I just don't bother. The BMS will do all the balancing for you...like your RC charger does, but for 20 cells at a time. You'll also be getting a power supply that can deliver 82 volts. We can talk about that later.
chargers...yes...I do build threads on just about everything...
Build your own charger: https://endless-sphere.com/forums/viewtopic.php?f=14&t=90292&p=1316096#p1316096
C80100 motor... I'd have to buy one for you, mod it and then send it to you. I want another one myself so if/when I get you one, I'll be buying at least one more for me. The C80100 on my Currie was a bit of a learning process. I ruined the factory motor shaft figuring out what I should do and how. That won't happen again. BTW...without really hard drills (I use carbide drills), you can't drill the shaft. Top of the line HSS bits will usually cut the shaft, but use oil becasue you will be bearing down and creating a lot of heat. Cheap HSS bits don't cut hardened shaft at all. I have the same issues with hardened sprockets and a few other things. Carbide bits while expensive and brittle and must be used with care, will drill anything...even other really hard drill bits that are not carbide. Using the wrong drills was how I botched the factory shaft. That and I ended up with several bits that couldn't cut butter afterwards!
drc said:
EG I can see you’re in the US California, right? Yes I’m bang smack in the middle of the UK (Leicestershire) .
so into the scooter stuff:
You mentioned a DC-DC reducer. Yes I fully agree this will be needed and I have no idea yet how to wire this up but I think I will get this sorted easily enough. My only issue I for see is will it fit with all the batteries and the new controller? but i like the idea of 12v as you say lights would be a fun option to explore.
The controller you have offered is a big yes please, could you firstly let me know the dimensions of it please. A few questions around the controller. Is there a way to wire up the throttle kill function for braking as I’m slightly worried that if ever the throttle sticks or it decides to run away I would have no way to stop it and if I do get a better motor etc I can see this being a worry for me. I guess this item will have the BT telemetry and the Mosfets you suggest? Also what do you do to the controllers to improve them?
As for the general wiring it will all changed as I replace and add items as the factory wiring is utterly shocking and adding big power would be bad .
The BMS offer is something I will take you up on when I get around to purchasing the lipos so thank you for that we will revisit that soon. I have not really looked into the BMS and what it does in depth. So, if I was to take the cell in the above link when it comes to charging the battery would be as easy as one or two plugs and set the charger up and leave it to do its job?
Chargers I think I will pick one up that can deliver the goods so I will be looking at the place you mentioned and doing research on this later. But if you want to make one im not going to object but lets see the battery option I go for.( thanks again) .
Going over to your question about the Chinese li-ion pack I have requested Samsung 30q cells and that’s about it . I will ask what the cell pattern would be and when I find this out I will forward it on. I have given the Chinese firm the correct dimensions ( taking a 0 off the earlier dimensions for space in the try lol). So lets see.
Your Alien power motor is this something that you would part with? Im fairly confident I could make a mounting plate/s for something like this .
Please drop me a PM re the controller and any other bits your willing to sell on and we can get that moving.
Thanks