Re: Street LEGAL Custom Bomber build! :-)
- Thread starter Dlogic
- Start date
The electrical parts list for installing turn signals is rather cheap. A 3 way switch plus the blinker relay and some wires cost under 10 €.
Getting some cheap chinese blinkers will add another 3-8€.
So it´s really no big deal and anyone can do it.
Next week a self retracting kickstand will hopefully be installed on my bike. That should conclude the long TÜV to do list of items to modify or add.
They will give me an appointment for the final inspection. With a bit of luck she will be street legal soon.
So many month, loads of big and small problems, endless research. It´s all coming to an end now. Can´t wait to give the bike another ride soon.
Getting some cheap chinese blinkers will add another 3-8€.
So it´s really no big deal and anyone can do it.
Next week a self retracting kickstand will hopefully be installed on my bike. That should conclude the long TÜV to do list of items to modify or add.
They will give me an appointment for the final inspection. With a bit of luck she will be street legal soon.
So many month, loads of big and small problems, endless research. It´s all coming to an end now. Can´t wait to give the bike another ride soon.
Yes, the bent metal bolted to the seat post is an illuminated license plate holder.
A total of 12 HK Nanotech 8000 mAh packs are used for the battery. This adds up to 18 cells *4p giving me 32 Ah.
Yup, she´s gotten fat and heavy. But that´s what you get when range is the key issue to deal with. A smaller battery would have saved a lot of KG, at the cost of less range.
A total of 12 HK Nanotech 8000 mAh packs are used for the battery. This adds up to 18 cells *4p giving me 32 Ah.
Yup, she´s gotten fat and heavy. But that´s what you get when range is the key issue to deal with. A smaller battery would have saved a lot of KG, at the cost of less range.
Dlogic said:
does your rear light have brakelight function?
good luck with the TÜV :wink: I also plan to get a license for my ebike. Will make it in early spring. They told me a special vehicle permission is about 500€
Is there a battery voltage limit in germany?
In austria it is about 60volts, but im not absolutely sure if the TÜV take care about this..
Fitted into the brake hose an hydraulic pressure switch activates the brake light when the lever is pulled.
The max voltage in Germany is 48 volts. New laws will be in place soon. So my build will still be legalised.
Even with this high voltage setup.
If used moderately, the battery gives me a usable range of 80 km.
That does include constant pedaling and speeds never above 50 Km/h.
The max voltage in Germany is 48 volts. New laws will be in place soon. So my build will still be legalised.
Even with this high voltage setup.
If used moderately, the battery gives me a usable range of 80 km.
That does include constant pedaling and speeds never above 50 Km/h.
Architectonic
10 kW
Dlogic said:The electrical parts list for installing turn signals is rather cheap. A 3 way switch plus the blinker relay and some wires cost under 10 €.
Getting some cheap chinese blinkers will add another 3-8€.
So it´s really no big deal and anyone can do it.
You left out the bit mentioning the nice custom bracket. :wink:
Allex
100 MW
Sorry for off top.
Martin, I believe you have 5403 and a Cromotor V2
How much current could those motors take without modifications?
I am thinking to upgrade my Bomber to have 100-120A peak battery current.
Will the stock bomber motor hold? Or do I need to upgrade the Phase wires/vent it to hold up? I am a very light rider and the covers of the motor are around 50C tops after a hard run @65A
Martin, I believe you have 5403 and a Cromotor V2
How much current could those motors take without modifications?
I am thinking to upgrade my Bomber to have 100-120A peak battery current.
Will the stock bomber motor hold? Or do I need to upgrade the Phase wires/vent it to hold up? I am a very light rider and the covers of the motor are around 50C tops after a hard run @65A
@ Allex
all you have to do is install a thermistor in the motor and watch over the temp.
If you keep it below 100-120°, you will not melt the windings or hurt the magnets.
I think the peak current limit also depends on how much torque the motor can handle mechanically (before the axle twist off).
i would say with 100A battery and 200A phase you should be safe (if you monitor the temp!). If the motor gets too hot very fast, you have to set to lower amps or buy a bigger motor^^
Vent holes are good, but you should coat the stator / inner motor parts with some waterproof paint if you want to keep the motor steady.
all you have to do is install a thermistor in the motor and watch over the temp.
If you keep it below 100-120°, you will not melt the windings or hurt the magnets.
I think the peak current limit also depends on how much torque the motor can handle mechanically (before the axle twist off).
i would say with 100A battery and 200A phase you should be safe (if you monitor the temp!). If the motor gets too hot very fast, you have to set to lower amps or buy a bigger motor^^
Vent holes are good, but you should coat the stator / inner motor parts with some waterproof paint if you want to keep the motor steady.
Yes, the motor will definitely take this current. I´m a tall and heavy guy with 1,98m * 94 Kg. That puts a lot of strain on the motor. Add my builds weight and you have got yourself one heavy setup to deal with. 
Especially during the hot summer month the windings got scary hot. After having vented the side covers the heat problem disappeared.
Underneath those drilled aluminum discs 4 big holes vent the motor. The discs are to prevent big debris from damaging the stator.
A clear coating was used to protect the stator and magnets from rusting.
Especially during the hot summer month the windings got scary hot. After having vented the side covers the heat problem disappeared.
Underneath those drilled aluminum discs 4 big holes vent the motor. The discs are to prevent big debris from damaging the stator.
A clear coating was used to protect the stator and magnets from rusting.
The self retracting side kickstand arrived today.
A new mounting plate to fix it to the swingarm will be fabricated tomorrow. That will conclude all the TÜV demands.
So with a bit of luck by next week the bike will get it´s final inspection.
I´m so exited now.
Will go for another test ride soon.
A new mounting plate to fix it to the swingarm will be fabricated tomorrow. That will conclude all the TÜV demands.
So with a bit of luck by next week the bike will get it´s final inspection.
I´m so exited now.
Will go for another test ride soon.
Allex
100 MW
Nice as usual, I see that you changed the stock phase/hall wires
Are the new phases thicker?
Are the new phases thicker?
Finished the self retracting kickstand.
Tomorrow the welded support for the swingarm that holds the kickstand will be powder coated.
This kickstand is a modified version from the east German motorcycle ETZ 150.
The only thing used are the 2 original springs plus the stands tube.
For a precise fit the black cast iron support, in the left side of the image, was remade out of steel sheets.
It looks better and is much lighter too.
Spent quite some time making all the pieces and welding them together.
Tomorrow the welded support for the swingarm that holds the kickstand will be powder coated.
This kickstand is a modified version from the east German motorcycle ETZ 150.
The only thing used are the 2 original springs plus the stands tube.
For a precise fit the black cast iron support, in the left side of the image, was remade out of steel sheets.
It looks better and is much lighter too.
Spent quite some time making all the pieces and welding them together.
madin88 said:A heavy bike needs a good kickstand
Do you have access to water jet cutting or are the steel sheets hand made?
nice work!
The steel sheets are all handmade. There's a company just a few Km from my place that laser cuts steel sheets.
Since they need a drawing with all the measurements I decided to make the prototype myself.
It takes many hours to figure out a folding steel structure. So for just a single piece this option was the fastest.
It should be possible to fabricate a good kickstand for around 30 to 40 €.
graucho
10 mW
You motivate and inspire. Thanks for all of the hard work showing your build so others can learn !
Here we go guys. After 2 years and 8 month my build is undergoing rigorous testing here:
So much work was done prior to my visit there for getting it street legal.
All the mechanical parts have passed the tests.
Here you can see the deceleration being measured while braking. The limit is 4 m/s. The Raptor does 8,1 m/s.
Tomorrow i will apply for a serial number that as to be engraved into the frame.
A list stating all the components is still pending. All technical drawings have been approved already.
They really liked the self retracting kickstand. Even under heavy use over rough terrain it stayed up.
Here´s a pic of the bike waiting to undergo more tests.
So much work was done prior to my visit there for getting it street legal.
All the mechanical parts have passed the tests.
Here you can see the deceleration being measured while braking. The limit is 4 m/s. The Raptor does 8,1 m/s.
Tomorrow i will apply for a serial number that as to be engraved into the frame.
A list stating all the components is still pending. All technical drawings have been approved already.
They really liked the self retracting kickstand. Even under heavy use over rough terrain it stayed up.
Here´s a pic of the bike waiting to undergo more tests.
izeman
1 GW
i want to see more
thanks for sharing so far!
thanks for sharing so far!
Well it´s a bit early to pour champagne into the glasses and celebrate, but at least they haven´t refused the whole project in General.
I have a lot of writing to do now.
Also a photo album of the build is needed to apply for a serial number. Just finished uploading loads of pics in order to get real paper prints.
PS: All the TÜV guys rode the bike around and where really pleased.
The ECE-R-100 will be the toughest part.
Updates will be posted here. It will take some time though. Some friends and myself will go trekking in Darjeeling the entire month of March.
I have a lot of writing to do now.
Also a photo album of the build is needed to apply for a serial number. Just finished uploading loads of pics in order to get real paper prints.
PS: All the TÜV guys rode the bike around and where really pleased.
The ECE-R-100 will be the toughest part.
Updates will be posted here. It will take some time though. Some friends and myself will go trekking in Darjeeling the entire month of March.
cal3thousand
10 MW
This is so awesome. Thanks for sharing everything. I have a new profound respect for Germany. This would never happen in the US. EVER.
Not sure how, but you've also managed to make me feel better about the quality of my car, having been made by your people
Not sure how, but you've also managed to make me feel better about the quality of my car, having been made by your people
Allex
100 MW
Mr. D, what kind wires did you use for the phases in your motor?
I would like to change mine in a 5403
Hope they have that kind in this store:
https://www.distrelec.de/home
I would like to change mine in a 5403
Hope they have that kind in this store:
https://www.distrelec.de/home
cal3thousand said:This is so awesome. Thanks for sharing everything. I have a new profound respect for Germany. This would never happen in the US. EVER.
Not sure how, but you've also managed to make me feel better about the quality of my car, having been made by your people
Thanks again to you and everyone else that is overloading this thread with compliments.
To be honest the freedom you have in the US when it comes to pimping, or building vehicles from scratch is second to none on the planet. There´s almost nothing that can´t be made street legal. All those laws and regulations here in Germany sometimes really give me a hard time.
Riding my build around Germany is considered a criminal offense.
Sad but true. It´s on the same step as selling drugs or harming someone else on purpose.
So, to prevent them from locking me up this is the only available option.
