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Posted on 13 June 2014 at 01:06 am (CET)

Past few days I've been busy drawing the whole wiring diagram. I'm pretty sure everything will actually be connected like this now. Only those 3 wires of the Battery Management System I'm not really sure about how to connect them yet. These are for drastically reducing the power when the batteries are empty so you can't undercharge them. But there should still be enough power to get the quad bike off the road safely. This can be connected in a few ways so I'll still wait with this.
Also made 2 extra circuits in it with a few buttons and relays. The one on the top left is for switching between low power (Drive Eco), high power (Drive Sport) and Reverse. And the one in the middle is for starting and stopping the charge process when the charge plug is connected. I might still get an actuator for this so the charge plug will get locked with this circuit while charging.

E-Streetquad Complete wiring diagram and a new working tachometer


Also have another new tachometer, this time one from Hong Kong for 10 euros. And third time's the charm, this one works perfectly.

E-Streetquad Complete wiring diagram and a new working tachometer


For the rest I've still been busy with the corner profiles on the side of the covers. Have to make quite a lot of cutouts in them for the cable glands and bolts. So this'll still take me a while. But for this battery box they're all done, still 3 to go.

E-Streetquad Complete wiring diagram and a new working tachometer

Posted on 5 June 2014 at 10:22 pm (CET)
Category: Batteries, General, Parts
Posted on 5 June 2014 at 10:22 pm (CET)
Category: Batteries, General, Parts

The corner profiles for the rear of the battery boxes are done. Now I still have to work on the ones for the front/cover but that'll take some more effort since I have to cut a few parts out for the cable glands and bolts.

E-Streetquad Steel corner profiles half done and some new enclosures


E-Streetquad Steel corner profiles half done and some new enclosures


I also bought some extra enclosures to place some other high voltage parts in. Bit easier than making something myself again. The DC-DC converter, sensor for the volt/amp meter and the main fuse will come in this large one. It'll be placed where the gastank used to be. It really fits perfectly, took a good guess for the sizes. It only wasn't available in black so it still has to be sprayed.

E-Streetquad Steel corner profiles half done and some new enclosures


E-Streetquad Steel corner profiles half done and some new enclosures


And this smaller one is for splitting up the high voltage cables to the DC-DC converter and charger and for both a seperate fuse. It'll be placed where the 12V battery used to be. It fits nicely as well and there's still enough space for the big orange cables which will run to the motor.

E-Streetquad Steel corner profiles half done and some new enclosures


E-Streetquad Steel corner profiles half done and some new enclosures


Then I also still have this one for some 12V things (main board for the Battery Management System and a few relais). Think I'll just place this one on top of the large enclosure, there's still some space for it.

E-Streetquad Steel corner profiles half done and some new enclosures


Tomorrow and in the weekend I'll continue again with the corner profiles so these can hopefully get welded next week.

Posted on 31 May 2014 at 11:55 pm (CET)
Category: Batteries
Posted on 31 May 2014 at 11:55 pm (CET)
Category: Batteries

Today I modified that small battery box a bit since this one didn't fit very well below the carbon front fender. First I just cut a small part off to try.

E-Streetquad Small battery box modified


But this just wasn't enough, so I had to cut off some more. Because of this I had to move the mounting points for the cover to the outside and there's also no clamp for the batteries on this side. But this isn't really a problem for this box since this will be placed almost straight up, the one clamp on the other side should be enough.

E-Streetquad Small battery box modified


Also made a new cover since this had to be a bit longer. The bending went pretty well.

E-Streetquad Small battery box modified


After that I made the holes in it, attached it and evened it out nicely. Then I tried fitting it again. Fits reasonably good now. Still not perfect but I can't cut anything off it anymore. If it won't work out like this I'll unfortunately have to modify the carbon fender a bit. But I think it'll be fine.

E-Streetquad Small battery box modified


And ofcourse also a new layer of EPDM rubber inbetween.

E-Streetquad Small battery box modified


Also rounded off the corners on all battery boxes where the steel corner profiles will come up against since the corner profiles are a bit rounded on the inside as well. So tomorrow I can finally start making the corner profiles to size.

Posted on 29 May 2014 at 12:29 am (CET)
Category: General, Parts
Posted on 29 May 2014 at 12:29 am (CET)
Category: General, Parts

Some good news again today, the mounts for the top case and rear lights are done. They're really nice looking again thanks to Geraets Metaalbewerking. It's always amazing to actually see something like this made from a drawing. Here are all the parts together.

E-Streetquad Mounts for top case and rear lights are done


Attaching them was a bit difficult, the mounts weren't the problem but ofcourse the Chinese welds again. Had to add quite a few rings again to get the mounts straight and make them fit. But it's not that bad, I think I just need to get some longer bolts now since the nuts are barely on there.

E-Streetquad Mounts for top case and rear lights are done


But eventually they were nicely attached to the frame.

E-Streetquad Mounts for top case and rear lights are done


E-Streetquad Mounts for top case and rear lights are done


And with the fender it just barely fits, it was meant to be this way but it was still pretty exciting if it would actually fit or not.

E-Streetquad Mounts for top case and rear lights are done


E-Streetquad Mounts for top case and rear lights are done


The lights and mounting plate for the top case attached. I thought I'd have to modify the rear light a bit so it could sit a bit lower but this is not necessary, fits just right with about 0,5 mm of clearance.

E-Streetquad Mounts for top case and rear lights are done


And then with the top case on there. Looks pretty nice, doesn't sit too high or too low. And also not too much to the rear which is usually the case with most of the top cases. It's also very firmly attached, if I try to move the top case the whole frame moves. So the mounts are definately strong enough as well.

E-Streetquad Mounts for top case and rear lights are done


E-Streetquad Mounts for top case and rear lights are done


Meanwhile I also modified an old power supply of a computer to be used as a 200W 12V converter. I can now easily use this to test some things sometimes. Much easier than having to charge that small 12V battery every time which is always empty again after 5 minutes.

E-Streetquad Mounts for top case and rear lights are done


I've also been busy modifiying the small battery box, but I'll probably show that tomorrow when it's done. This weekend I'll start on making those steel corner profiles to size.

Posted on 22 May 2014 at 10:46 pm (CET)
Category: Charger, Drawings, General, Parts

I've made some drawings again. These will probably be the last 2 aluminium parts that still have to be made. First is a mounting plate for all the gauges and switches. This will be mounted on the handlebar.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


As usual I made a paper model of it to see how everything would fit.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


It all fits pretty good, just the angle of the gauges isn't really that great. Would be better if the plate could be bent to an angle of about 20 degrees, would be looking straight at the gauges then when sitting on the quad bike. I modified the drawing a bit to make this possible. Also made some small changes to make it easier to route and added another hole for the hazard lights switch. The plate will be bent by about 20 degrees on that line in the middle.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


To be able to measure a few more things I had to place the fenders again. So here's a nice picture of the whole quad bike. It's actually starting to look like something.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


I just ran into a problem with the battery box that's in the front below the carbon fender. It barely doesn't fit and the box is being pushed against the steering shaft which isn't a good thing. So I'll have to modify this box a bit, make it beveled on one side. Because of this I also haven't been able to saw the steel corner profiles to size yet since they'll have to be different for this box as well.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


Then there's still the other plate. This one's for the charge inlet and will be in the same spot where the gas filler cap once used to be. For this I needed all the sizes of the fender which is quite tricky since the lines aren't straight but bent just slightly. I had the idea of just sticking a piece of paper on it and then try to find the lines with a pencil, worked pretty well.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


Now I could easily measure everything while drawing without having to take the whole fender with me.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


I again made a paper model of it and it all fits perfectly, no modifications needed.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


The charge inlet is new after some advice from Rebbl, this is a mode 3 type 2 (IEC 62196). It's the standard everywhere in Europe now for all electric vehicles. Last year or so I already bought a CEE inlet but meanwhile this won't be approved anymore at the RDW (our institute for road safety). So unfortunately I had no choice but to buy this one. But I'm quite happy with it now, it's much more solid, safer and also waterproof.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


E-Streetquad Drawings and fitting of plates for the gauges and charge inlet


Also bought a new analog tachometer for a very cheap price. But unfortunately I can't get this one to work either. I was really sure it would work with this one since it normally gets connected to the alternator and also gets a pulse signal. But it doesn't do anything with the pulse signal that's coming from the controller. So I'll have to look for a solution again.

E-Streetquad Drawings and fitting of plates for the gauges and charge inlet