Posted on 26 June 2014 at 11:48 pm (CET)
The corner profiles are all welded now thanks to Van Alphen Lasservice. Done very nicely again by the same welder that welded the blocks onto the rear swingarm back then. He also grinded off the welds on the outside already. I still had to grind some off myself on the inside to make everything fit well.
I just wonder how it'll fit once everything has been sprayed but I guess we'll just have to wait and see. There's also no clearance at all anymore now between the frame and the 2 big battery boxes so it's important now that the mounting points will get welded in exactly the right spots. But I'll still have to make them all, will keep me busy for a while.
Posted on 21 June 2014 at 11:14 pm (CET)
The corner profiles which are going to be holding the battery boxes in place are finally all done.
For the small box I had to do something different, this will be 2 seperate parts which can be attached to eachother and also to the frame. But you'll see this when it's welded, it's hard to explain.
Here's everything together. It all fits perfectly and is ready to get welded now. I'll only get these corner profiles welded first, it's a bit easier to see where the mounting points will have to come once everything's stuck together.
Hopefully this can be done coming week but after that it'll take some time again to make all the mounting points.
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.
Also have another new tachometer, this time one from Hong Kong for 10 euros. And third time's the charm, this one works perfectly.
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.
Posted on 5 June 2014 at 10:22 pm (CET)
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.
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.
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.
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.
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)
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.
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.
Also made a new cover since this had to be a bit longer. The bending went pretty well.
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.
And ofcourse also a new layer of EPDM rubber inbetween.
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.