Posted on 27 September 2014 at 12:04 pm (CET)
Category: Wiring (12V)
The last few days I've been been busy filling up one of the boxes with components and wiring them all up. Quite a challenge to stuff as much as possible into it. The plan was to get all this in.
I just started wiring up the 2 bigger relays, these are for the 3 drive modes (low power, high power, reverse). All wires are soldered directly onto the contacts. The mounts for these kind of relays take up too much space.
I wanted to do the same with the small relays but this wasn't such a good idea. They still took up too much space to be able to place them in the same box. The contacts also kept breaking when I was moving the wires a bit.
So for these I still bought some circuit boards and they will come in a seperate box. Should still have some space for that on the quad bike.
Already soldered the relays onto them. With some spacers inbetween the circuit boards I can stack 3 of them.
But that box will come later, still have to start on it. For the other box I was working on I made a plate that fits right in. I can screw all of the components onto that. Also wired these all up already. The bigger one is the main board for the BMS (Battery Management System) and the smaller one is to convert a pulse signal from a switch to on/off.
And here's everything in the box, it all barely fits. There are quite a lot of wires that have to go outside of the box. Still have to get some cable glands that I can place in the box but I'll wait with that untill I have the other boxes done as well.
Later on I'll have some more news if all goes well, in any case I'll have enough to do again this weekend.
Posted on 23 September 2014 at 11:12 pm (CET)
My sister had a little surprise for me today. While I was busy making some space so I could turn the quad bike around she was already spraying a layer of epoxy on all of the aluminium parts. This was actually going to be done next week so that was definately nice to hear. She also sent a few pictures again.
Here before spraying. All parts were also sanded a bit.
And after spraying.
This Saturday they will all be sprayed in the same color as the frame and I can take them home again. I'm really curious how these parts will look like in that nice color.
Tonight I only made some space and turned the quad bike around so it's easier for me to work on. A few of the black parts are also attached now. Looks very nice in combination with the white, just can't really see it well yet in the picture.
The coming days I'll probably be busy with some of the smaller boxes already placing some electric components in them.
Posted on 22 September 2014 at 11:24 pm (CET)
Tonight I continued again. The wheel hubs with brake discs and the bumper are now attached. And the quad bike can stand on the ground again at the front since the wheels are also on it already.
Also placed the POM bushings in the rear swingarm already so it's ready to get attached as soon as the motor is on there. But untill then the quad bike still has to stay off the ground at the rear.
The front brake system and the track rods I also can't attach for now. The steering shaft and handle bar has to be attached for this first. But the part the keeps the steering shaft in place will be sprayed together with the aluminium parts. This part also got back from the sandblaster very late, that's why it hasn't been sprayed yet. Think I can only continue with a few of the black parts now. Meanwhile I'm running out of space here, the quad bike keeps getting bigger but there are still many parts on the floor. So I'll first have to see how I can deal with that.
Posted on 22 September 2014 at 12:25 am (CET)
Today I managed to solve the problem with the car pretty fast so I still had some time this evening to continue with the quad bike. I greased all of the ball joints some more and placed new dust caps on them. Then I just continued a bit longer than usual so I could still attach both of the steering knuckles and upper swingarms. It's really starting to look good already. Also those black POM bushings really match well with the color of the frame. I think with white POM bushings it wouldn't have looked as good.
Tomorrow I'll continue again with the wheel hubs, brake discs and the wheels themselves. I only can't attach the rear swingarm yet, the motor will have to go on there first but I need the aluminium parts for that. So this will still have to wait. I can already place some of the black parts though and maybe even start with the batteries already. In any case I have enough to do now.
Today was a very exciting day again. All parts of the frame were sprayed in the beautiful color Bianco Canopus. I've seen this color on pictures with Lamborghini's often but never on a frame so I really had no idea what it'd look like. But I'm really happy that I chose this color. It looks really great, especially when there's some light shining on it. And my sister has done a really good job again, don't think anyone could get it any better looking than this.
As usual here's a picture again before the spraying. The layer of epoxy is a bit sanded here so it already looks like matte white.
And after the spraying. Much light in the spray booths so it already looked very nice.
Wrapped everything again to get it home without any damage. It all barely fits in my car.
At home I unwrapped everything again and right away I placed a fender on it to see the combination of the 2 colors. I think it looks really awesome. I made these pictures with flash so you can see a little how this color looks like with some light shining on it. But outside with sunlight, and also with you own eyes, it looks even better.
Tonight I already started building it up. First I placed the new SKF bearings and glued the magnet for the speed sensor.
Then I attached the lower front swingarms with the POM bushings in it and the shocks to the frame. Pretty fun knowing that this is finally the last time attaching everything.
Also placed the shock covers already. Looks a bit odd still but I kinda have to see it when everything is attached.
The plan was to spend the whole day tomorrow to continue building it up but unfortunately I have a problem with my car that has to be fixed before Monday so I think I'll be working on that the whole day tomorrow. So the quad bike will still have to wait a bit.
In about 2 weeks the last parts will also be sprayed. These are all of the routed aluminium parts. So I'll have to be patient with those again but if they turn out the same way then it's definately worth the wait.