Trenavix
1 mW
- Joined
- Feb 4, 2021
- Messages
- 18
I did share a peek of this in the general bombers thread, but felt like I should make a thread for it at some point.
Here are Gen1 & Gen2 on an old site of mine.
What I've done since I've moved back to the states from Finland a couple years ago, is combine these two bikes into the best they can be as one.
The KTM EXC front-end is too big and heavy for the bomber frame, ended up cracking it around the head tube area, thus I stuck with the DNM-USD8 as it is much lighter.
I swapped the QS273 stator for a very high Kv one I had in a closet, that can potentially hit 140km/h with a fully charged battery, no field weakening.
The battery on Gen2 was an IED built by UPP that I tried to improve with updated lead wiring (2AWG) and an ANT BMS, but still, some cells were fried by then and it was just a terrible idea to have 400 cells in a single pack. They were good cells though, Samsung 35E's.
My bikes were in Cali, and I moved to Washington shortly after returning to Cali. I gutted Gen2, and stuffed its parts in the backseats of my car, and had Gen1 intact on a hitch on the back.
Gen1 was usable, and I fitted 2 72v "cargo packs" into parallel for it to be used.. Said cargo packs were meant for Gen2's pannier bags, but Gen1 needed some battery for a bit.
After getting settled in Washington, I ripped apart the 400 cell battery pack and tested all cells for the ones with best IRs (after a bit of charging on all individually).
I found that, if not grinding the sides off of the bomber frame (after Gen2, I recommend NOT grinding sides off - it hurts stability), I could fit a maximum of 360 cells in the frame if going with 20s. Which is 18p.
Many months of slow work and eventually I built it. 3 sub-packs wired in series with external BMS on top. Everything fit exactly as planned, and was definitely a hard cram.
I then used the cargo packs exactly as planned, in panniers. Altogether, the bike is 20s28p, 7kWh.
It can push a maximum peak of 364A (almost 28kW with voltage sag)
October 2023, I registered my motorcycle. I rode it to Washington State Patrol in Marysville, and they did a VIN inspection, and granted my bomber a VIN plate. I could then take it to the DOL and it was granted a plate, after I showed all my part invoices. Insurance through SafeCo is $92/year.
I have 39000km on the odometer as of posting, 21.5k of those km are in the past year, with the new battery setup. I frequently ride into Canada on my motorcycle, sometimes into the Cascades, off-roading frequently, and almost every single 60km work commute from Edmonds to SODO (Seattle) is on it.
I also had some issues with water ingress on my qs273. I have had to replace the halls a few times now due to rust on the rotor magnets.
After some lurking in threads here, I found that insulating varnish could prevent the rust and keep it going for many years, so a couple weeks ago, I coated both the stator and a new rotor in EL600. Hope it plays out well.
I'll post some important pictures below.
Some other eventual upgrades were:
-Kickstand: Directly tapped into the swing-arm, closer to the pivot point
-Dual front-brake callipers (I hand-crafted the second adapter mount for the DNM forks from aluminium),
-Reinforced steel plate on the swing arm for the shock's force (custom welded)
-New pannier bags (2x batteries fit in one bag, my large 3kW charger fits in the other bag)
-Reinforced steel cargo bag brackets, custom made
-Heated grips via 12v splice (Needed for Washington winters)
-Reverse switch wired to "engine start" button (hold the button and throttle, wheel goes backward)
-Better handlebars (slightly raised, more like dirtbike)
1 Single Cargo Pack:
Here are Gen1 & Gen2 on an old site of mine.
What I've done since I've moved back to the states from Finland a couple years ago, is combine these two bikes into the best they can be as one.
The KTM EXC front-end is too big and heavy for the bomber frame, ended up cracking it around the head tube area, thus I stuck with the DNM-USD8 as it is much lighter.
I swapped the QS273 stator for a very high Kv one I had in a closet, that can potentially hit 140km/h with a fully charged battery, no field weakening.
The battery on Gen2 was an IED built by UPP that I tried to improve with updated lead wiring (2AWG) and an ANT BMS, but still, some cells were fried by then and it was just a terrible idea to have 400 cells in a single pack. They were good cells though, Samsung 35E's.
My bikes were in Cali, and I moved to Washington shortly after returning to Cali. I gutted Gen2, and stuffed its parts in the backseats of my car, and had Gen1 intact on a hitch on the back.
Gen1 was usable, and I fitted 2 72v "cargo packs" into parallel for it to be used.. Said cargo packs were meant for Gen2's pannier bags, but Gen1 needed some battery for a bit.
After getting settled in Washington, I ripped apart the 400 cell battery pack and tested all cells for the ones with best IRs (after a bit of charging on all individually).
I found that, if not grinding the sides off of the bomber frame (after Gen2, I recommend NOT grinding sides off - it hurts stability), I could fit a maximum of 360 cells in the frame if going with 20s. Which is 18p.
Many months of slow work and eventually I built it. 3 sub-packs wired in series with external BMS on top. Everything fit exactly as planned, and was definitely a hard cram.
I then used the cargo packs exactly as planned, in panniers. Altogether, the bike is 20s28p, 7kWh.
It can push a maximum peak of 364A (almost 28kW with voltage sag)
October 2023, I registered my motorcycle. I rode it to Washington State Patrol in Marysville, and they did a VIN inspection, and granted my bomber a VIN plate. I could then take it to the DOL and it was granted a plate, after I showed all my part invoices. Insurance through SafeCo is $92/year.
I have 39000km on the odometer as of posting, 21.5k of those km are in the past year, with the new battery setup. I frequently ride into Canada on my motorcycle, sometimes into the Cascades, off-roading frequently, and almost every single 60km work commute from Edmonds to SODO (Seattle) is on it.
I also had some issues with water ingress on my qs273. I have had to replace the halls a few times now due to rust on the rotor magnets.
After some lurking in threads here, I found that insulating varnish could prevent the rust and keep it going for many years, so a couple weeks ago, I coated both the stator and a new rotor in EL600. Hope it plays out well.
I'll post some important pictures below.
Some other eventual upgrades were:
-Kickstand: Directly tapped into the swing-arm, closer to the pivot point
-Dual front-brake callipers (I hand-crafted the second adapter mount for the DNM forks from aluminium),
-Reinforced steel plate on the swing arm for the shock's force (custom welded)
-New pannier bags (2x batteries fit in one bag, my large 3kW charger fits in the other bag)
-Reinforced steel cargo bag brackets, custom made
-Heated grips via 12v splice (Needed for Washington winters)
-Reverse switch wired to "engine start" button (hold the button and throttle, wheel goes backward)
-Better handlebars (slightly raised, more like dirtbike)
1 Single Cargo Pack:
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