Stand-up escooter, ze Meduza project

[agniusm]

Here we go, decided to build something cheap before my cargo bike project in the summer.
The system:
36V
1kW Hub motor
30A controller
simple BMS
5A DC-DC converter
12S A123 prismatic cells (upgradeable to 24S) 20AH
full throttle
Light switch, front rear lights, stop light
Horn (nasty one)
Old style voltmeter (Probably not)

Color scheme: Box, steering - graphite, all the tubing, forks - bright red, fenders, rims - white.
________________________________

Here is the donor bike i picked up for 30USD:

The box for battery and all the electric components:

It does look like coffin, steampunk baby


Welded frame and rear fork:

Steering:

Rear tire:

A123 battery mount:

Thanx

 

[agniusm]

Got some more work done this weekend, looks like its turning out to be long low rider. Here are some photos:

Next some cleaning to do on the frame. After will fit all components, weld some studs to mount controller, charger, DC-DC etc.

 

[sk8norcal]

looks good, very nice...
hopefully that headtube weld will hold up...

 

[agniusm]

looks good, very nice...
hopefully that headtube weld will hold up...

Thanks. I will need to adjust head tube angle, but the weld is pretty beefy, should be ok.

 

[agniusm]

Got round to do some more work. Adjusted the seat and mounting as well increased angle on the rear fork. Feels good now. Some Photos:

 

While i was in UK picked up kids electric scooter from scrapyard. Just remembered that i have it. Will be using brake handlebar for electric-manual combo brake:

Got round to fit my iCharger 206B with PC PSU (120W 12V rail) and cables to charge and test my A123 cells. So far one is 18.4AH, the rest hoovers around 19.8AH-19.9AH, i am making a list with ID numbers and capacity, will publish on google docs soon:

 

 

Interestingly, the 18.4AH cell felt gelish inside. Also it was marked -B- in the middle??!!
Next will be making enclosure between front sections for instruments and charging cable.

 

[kfong]

Cool scooter design.

 

[Brentis]

Great job.
I am always impressed with custom rides.
I like the look a lot.

I hope you aren't offended by me using your pic/suggesting a mod.
Consider a brace from seat post, to frame. On each side.(red)
To help distribute rear suspension forces.(BlueGreen)
There is a lot of stress on the seat post(white circle).
Maintains an open look.



Thanks for all the pics

I'll stay tuned for final battery setup.
Good luck.

 

[agniusm]

Hi. Here is the link for list of cells with capacity test. I have included different markings that appear on some cells:
https://docs.google.com/spreadsheet/ccc?key=0Ap6NVZIdTBFOdE1zXzN3ZzhyYkoxb0g2WjJuSmdiX2c

Great job.
I am always impressed with custom rides.
I like the look a lot.

I hope you aren't offended by me using your pic/suggesting a mod.
Consider a brace from seat post, to frame. On each side.(red)
To help distribute rear suspension forces.(BlueGreen)
There is a lot of stress on the seat post(white circle).
Maintains an open look.


Thanks for all the pics

I'll stay tuned for final battery setup.
Good luck.

Thanx for the suggestions. Not offended, this is why i post this here, to get feedback and squeeze most of the build.
I was thinking about putting braces on each side as you suggested, but it makes difficult to put single cover on the whole box. I thought i will try this way and see if it is strong enough. If it breaks than just redo. The whole scooter will weigh no more than 70 and 80kg including the raider (my wife or me).
I have a question thou. i will be putting 5A DCDC converter for lights, horn etc., can i ground negative to the chassis so i could run single wire for lights etc. or on electric better not?

 

[agniusm]

Got lights fitted, found some old style from Russian motorcycle -IZ-. They fit pretty nicely. Also got rear fender attached.

 

 
And here is with me, for size reference. I am 178cm tall.

 

[EBJ]

wow.
This thing is really coming along.
Nice work. Can't wait to see the finished product!

keep us posted like you have been.

 

[EBJ]

Oh, I also agree with Brentis.
I'm sure you can figure out a good way to brace it and still have an easy battery-cover access.
You don't have to put a big beefy brace in there, but I think it really needs something (it could even be bolt-on)

 

[agniusm]

Oh, I also agree with Brentis.
I'm sure you can figure out a good way to brace it and still have an easy battery-cover access.
You don't have to put a big beefy brace in there, but I think it really needs something (it could even be bolt-on)

Thanx for comments. I will look in to that. first will need to get a sheet of aluminium for the cover and then see what could be done with bracing.

 

[agniusm]

Some progress:

 

[agniusm]

Got some bits for building the battery:

 

[agniusm]

Started working on battery pack, did not measured twice and got the brass blocks wrong.
Here is some pics on BMS mounting and plates for cells:

 

[agniusm]

Hi, need some help with connecting all the components. Basicaly regarding battery cut off switch and circuit breaker. Where is the best place on the circuit to place battery cut off switch, see the BMS picture, i think before it goes to BMS and controler and circuit breaker between controller and battery?
Thanx

 

[agniusm]

Here are some parts i have aquired:
12V 6A DC-DC

Charger:

Got some screws for building pouch cell pack, for the brass block:

 

[agniusm]

OK, got some time to work on battery pack. Starting to take shape, all the ideas turned out to be ok.
Using 6x6 @45mm brass blocks, half threaded 3M half drilled 3.5mm and countersunk 1mm deep. Bolts - 3mm DIN7991 Stainless Steel Alen head:

 

[agniusm]

Have rearranged battery for better BMS access if things go tits up:

 

Winter pleasures:
[youtube]ypDzzZ0Jzw0[/youtube]

[youtube]GblPW77Xv6c[/youtube]

 

[agniusm]

Some updates:

Having issues with my BMS/charger. Here is my post from other thread:

Hi, found this thread by accident, thought will post here about my issue with this BMS and somebody might have a solution for me. I have all hooked up and it looks like BMS isnt working. When i connect + to BMS, charger kicks in for few seconds and goes out and after about 10 seconds dose same and stays off. When i hold + wire to bms between my hands (being bms in one hand, battery in the other) it starts working ok. It is some kind of mystery.
I am using it on a123 20Ah cells in 12s configuration with 5a charger. All cells range from 3.3 to 3.36 volts. Any input would be welcome.
Here are
[youtube]B0PJC5MexUw[/youtube]

-

[youtube]dSI0PDfBsNc[/youtube]

 

[agniusm]

Bought some LED lights. Will be using domestic 5W Edison bulbs, MR16.

10 degree for high beam:

38 degree for low beam

Heres how they look:

They fit near perfect in to those lights, just neet to cut out round perspex piece in front of the LED

 

[agniusm]

Charging cable:

 

[Brentis]

Have rearranged battery for better BMS access if things go tits up:

 

...

Following this thread,
I feel inspired to build my own pack now. :wink:

Keep up the great work.

 

[agniusm]

Thanx mate. Yea, spring is coming, need to finish it soon. The bike is gone to the painters, waiting or the spokes to arrive from TW, will need to lace two wheels, will be first time

 

[agniusm]

Got some work done. Still need to get the wheels trued.