Vespa PX125 (Large Frame) Electric Conversion.

JimVonBaden · Dec 28, 2020

As some of you may know, I am building an electric Vespa. The following thread is me working through it, hopefully with some knowledgeable help from here.

I am starting with this:

I started out going down the restore path, then I bought an ebike, and found forums like this.

Currently I am here:

Lots of work to this point, but still could go stock, but the bug has bitten.

I have a substantial initial list, with the help of Allen:
• QS 205 10 inch hub motor 72v 4000W
• https://qsmotor.en.alibaba.com/product/60740294754-801640143/QS_Motor_10inch_4000W_205_55H_V2_Type_Hub_Motor_for_E_Scooter.html
• Battery is 72v 24.5 Ah rectangle from Em3EV (Allen's) Shape 195 x 230 x 140mm, or 7.7 x 9 x 5.5 inches
o No links yet, but going with the same battery size as you, suggestions welcome
o Maybe https://www.aliexpress.com/item/4001029160957.html?spm=a2g0o.productlist.0.0.2a3633f0FXMwk8&algo_pvid=330c5ebd-f778-4ada-ad86-66eae15beac7&algo_expid=330c5ebd-f778-4ada-ad86-66eae15beac7-24&btsid=0bb0624016090101225861122e2b75&ws_ab_test=searchweb0_0,searchweb201602_,searchweb201603_
• Controller:
o https://kellycontroller.com/shop/kls-h/
o 72V, 80 amp continuous, 200 amp peak
• Brakes
o https://www.amazon.com/BRAKE-MASTER-CYLINDER-CALIPER-ASSEMBLY/dp/B00EGSHBOA
• Misc
o From Kelly:
o 1*x J1 Cable $19.00
o 1*x HWZ Series DC/DC Converter 96V to 12V https://www.amazon.com/Pro-Chaser-regulator-Scooters-Bicycles/dp/B07B6B6HQZ/ref=sr_1_3?crid=3EMG62LEM5BTL&dchild=1&keywords=84v+dc+to+dc+converter&qid=1608754208&sprefix=dc+converter+84%2Caps%2C191&sr=8-3
o 1*x KBL96251,24-96V,250A,BLDC Controller/With Regen
o * - Ultra High Speed Motor Option: checked
o 2*x CNL 500A Fuse
o 1*x Emergency Contactor KEMG-125A 125A continuous
o 1*x KBL/KEB J2 Cable
o 1*x Optional Waterproof(KEB/KEB-X
o 1*x Fuse Holder(Ceramic) $7.00
o http://www.eastgem.net/throttle-adapter.html

I have two issues that I need to address before I move on. First the battery. I could go with home built, but not sure I have the knowledge to do it myself. This is what I have so far:

I could also use Allen's (195 x 230 x 140mm, or 7.7 x 9 x 5.5 inches) but am hoping for more Amp Hours. Suggestions for a vendor?

The other problem is, the vespa swingarm is part of the motor, and I need a standard-ish swingarm to connect my Vespa to my motor.

Something like this shape, but tubular off a regular MC or scooter.

I'll post my progress, but would love some more input!

Thanks,

Jim 8)

JimVonBaden · Dec 28, 2020

Next iteration. After doing some new measurements, and adding some ideas, I came up with this.

Before:

New swingarm (mock-up):

Measurements and ideas. Note one side is longer to accommodate the torque lever. I'd slot the ends of the swingarm to allow insertion of the motor. Green arrow is pointing to the locator tube. It will be removed when fully welded.

The arms are doubled 3/8" bar stock, welded together, and 1/4" web bracing.

Thoughts?

JimVonBaden · Dec 29, 2020

Updated swingarm design.

JimVonBaden · Dec 30, 2020

Battery ordered: 72v 38ah With 150A BMS eon lithium ICR21700 cells, $1K :shock:

More about to be ordered:
* Electric Motor QS Motor 10inch 205 4000W 72V 85km/h
* Controller Kelly QSKLS7245H
* HWZ Series DC/DC Converter 96V to 12V
* Hydraulic Brakes Electric Scooter Disc Brake Set for Motorcycle
* J1 Cable
* 2*x CNL 500A Fuse
* Emergency Contactor KEMG-125A 125A continuous
* KBL/KEB J2 Cable
* Throttle
* 10 AWG copper wire
* H4 LED headlight
8 LED lights for tail and turn signals, as well as speedo
* much more as I go.

Still refining the swingarm.

JimVonBaden · Dec 31, 2020

Update on the swingarm.

JimVonBaden · Jan 4, 2021

1*x HWZ Series DC/DC Converter 96V to 12V (in kit)
ebike throttle
Electric Motor QS Motor 10inch 205 4000W 72V 85km/h
Kelly Sine Wave Controller KLS7245H with IP66
Brake kit
34ah 72V battery, custom made
Display, controller
J1 Cable
2*x CNL 500A Fuse
Emergency Contactor KEMG-125A 125A continuous
KBL/KEB J2 Cable

All ordered, $2K in parts! Yikes, I hope it works!

Ryaned · Jan 4, 2021

Great project, do you have a youtube channel to follow your progress?

JimVonBaden · Jan 4, 2021

I do have a youtube channel, but I haven't posted on this, except for my original video of it before I decided to go ebike.
https://youtu.be/HTneUGxI_aA

That said, I just may make a progress video.

Thanks,

JimVonBaden · Jan 6, 2021

SlowCo · Jan 6, 2021

Nice work :thumb:
That's going to be a very nice EV conversion!

JimVonBaden · Jan 6, 2021

I'm comfortable with body and paint, comfortable with mechanicals, reasonably comfortable with welding, very comfortable with wiring, but know only a little about ebikes, so this should be interesting. It may turn out to be a great looking art piece!

JimVonBaden · Jan 6, 2021

Ready for primer. I can't go any further until I receive the primer. I wont paint it until I have all the electrical in place for fit. I may need to do some more fab. Next up the front suspension and rear shock. I have a new handlebar holder and cover, so minimal work there.

mannydantyla · Jan 8, 2021

Nice job on the swing arm, that is probably how I would have done it as well. What do the drop outs look like? Is there some sort of clamp or anything? I also am getting a QS 4kw hub motor for my build so I would love to see how others are doing it.

Cheers!

JimVonBaden · Jan 8, 2021

mannydantyla said:
Nice job on the swing arm, that is probably how I would have done it as well. What do the drop outs look like? Is there some sort of clamp or anything? I also am getting a QS 4kw hub motor for my build so I would love to see how others are doing it.

Cheers!

I'm not sure yet. Once I receive the motor and brake I will finish the configuration. But, it will look a lot like this:

It is from EddySPalm here: https://endless-sphere.com/forums/viewtopic.php?f=10&t=89582&start=100

JimVonBaden · Jan 8, 2021

Battery maker just finished the battery. I should have it next week.

JimVonBaden · Jan 9, 2021

The wiring on the scooter will be all new. This is my current (pardon the pun) take on it.

For the motor, battery and controller electrics:

For the scooter electrics:

Motor electrics borrowed partly from the internet.

JimVonBaden · Jan 9, 2021

Parts are starting to come in:

DC DC converter from 72V to 12V. Amp/Volt/Current meter. 300amp circuit breaker.

markz · Jan 9, 2021

Looking good!

Its always nice to have a garage you can work in, a man cave.

JimVonBaden · Jan 9, 2021

markz said:
Looking good!

Its always nice to have a garage you can work in, a man cave.

Definitely helps!

Garage:

Attached workshop.

But I have seen amazing work on a dirt porch too. :bigthumb:

mannydantyla · Jan 10, 2021

Thank you for sharing your wiring harness diagram! I'm saving that to my desktop to study

I would love to know what Amp/Volt/Current meter that is too.

JimVonBaden · Jan 11, 2021

mannydantyla said:
Thank you for sharing your wiring harness diagram! I'm saving that to my desktop to study

I would love to know what Amp/Volt/Current meter that is too.

These are better:

Thanks again to Resistor for helping me work through the motor wiring. I think I am getting close. I completely redid the motor diagram, and updated the bike wiring. I am using a new fuse block, and completely hand wiring the bike. I plan to reuse the switches as much as possible, and adding a device that will translate the throttle cable to electrical impulses to keep it stock as possible looking. The clutch lever will be repurposed, or replaced, with a rear disc brake set-up.

Just waiting on all the parts to come in. So far I have the Inverter, 72V to 12V 25 amp, the main battery cut off, and the amp/current meter in hand.

Battery should be here this week, and the motor and controller plus brake mechanicals next week.

Here is the meter: https://www.amazon.com/gp/product/B07T9LV66P/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

mannydantyla · Jan 11, 2021

yes that is even better, thank you very much

Did the amp meter come with the shunt (that's what that is in your picture, right?) and where in the wiring diagram is the shunt located?

Sorry for all the questions. I'm finding the the learning curve to be a steep one.

JimVonBaden · Jan 11, 2021

mannydantyla said:
yes that is even better, thank you very much

Did the amp meter come with the shunt (that's what that is in your picture, right?) and where in the wiring diagram is the shunt located?

Sorry for all the questions. I'm finding the the learning curve to be a steep one.

It did, and it is incorrectly labeled a fuse 200 amp.

mannydantyla · Jan 12, 2021

JimVonBaden said:
It did, and it is incorrectly labeled a fuse 200 amp.

Oh then that also helps explain why there was two fuses! :lol: Sorry I wasn't meaning to poke holes in your wiring diagram haha.

JimVonBaden · Jan 12, 2021

mannydantyla said:
JimVonBaden said:

It did, and it is incorrectly labeled a fuse 200 amp.

Click to expand...

Oh then that also helps explain why there was two fuses! :lol: Sorry I wasn't meaning to poke holes in your wiring diagram haha.

Poke away. Better to find my mistakes now versus causing my controller or battery to burn for bad wiring. :shock:

Vespa PX125 (Large Frame) Electric Conversion.

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