Posted on 16 May 2014 at 01:26 am (CET)
Another small update. A few days ago I already got the steel corner profiles, strips and a plate for the battery boxes and charger. It weighs quite much all together. Wanted to try and saw this by hand with a mitre saw but after half an hour I only sawed one profile so I stopped. Meanwhile I've bought an electric mitre saw which can be used for wood, aluminium and steel, will always be worth it's money that way. Tomorrow or this weekend I'll be able to continue again with sawing the profiles.
But that wasn't all yet, I also went shopping on Ebay (will have to be careful with this, already seen many nice things) and got a new throttle with grips. Not to make it look better or anything like that because they look pretty much alike and are still Chinese but this is one with a hall sensor built in. Now I won't have to use the seperate potentiometer anymore where the throttle cable was attached to. And also won't need a throttle cable anymore. That's probably the best thing because I still remember really well from my scooter era how annoying these throttle cables can be when they suddenly break. Now there's a cable going straight from the throttle to the controller, or like they call it drive-by-wire. They're a bit shorter than the original and closed on the outside so everything's moved a bit more towards the ends of the handle bar. Will have to wait and see if I like it this way, otherwise I could just cut off a small part of the handle bar on both sides. Also bought a 2nd set of these as backup, they're still Chinese ofcourse. Was pretty cheap anyway.
I also wanted to move the mounting points for the mirrors a bit, it went well on one side but on the other side not so much. This is what happens when you overtighten them just slightly.
Also received a new digital dashboard today. Trail Tech Striker with seperate dashboard around it and a seperate tachometer.
It all looks nice and it's quite a bit smaller than I thought it'd be. But today I also tested that seperate tachometer and unfortunately it doesn't work. Normally its wire just gets wrapped around the spark plug lead to get the pulse signal but this can't be done with mine. The controller does have a function to pass on the pulses of the RPM sensor but when I connect to tachometer to this it unfortunately doesn't do anything. Already contacted Trail Tech about this en according to them this indeed can't be done since it's inductive and needs high voltage (like with an ignition coil). So I can't do anything with this unfortunately. Will have to see if I can send it back. The Striker dashboard I still haven't been able to test yet but I don't expect any problems with this, should all work well.
On Ebay I also still found some rubbers that go around the connectors for the charger and DC-DC converter. This way it'll all last a bit longer again if no water/moisture can enter.
Today I also found out that I received the wrong contactors a year ago (for reverse and another one to turn on and off). I ordered them for 72V with 12V coil but instead I now have them with 72V coil. No idea how this could have ever gone wrong because what use is a 72V coil when you're actually switching 72V as well? Seems pretty obvious that this should've been 12V but oh well. Going to contact that company where I bought them from and see what they can do. That was about it for today.
Posted on 3 May 2014 at 12:26 am (CET)
Besides the battery boxes there's still something else that has to be attached to the frame, the charger. Today I checked how it would fit and what I'll have to make for this. Thought I'd show how it'll be placed, don't think I've showed this yet.
It'll be placed as high as possible so I can still easily get the large battery box in and out without having to remove the nerfbar, pedals and heel guards. But I won't bother thinking too much about how to attach this. There are already 4 mounting points on there (also 2 on one side but I'll have to cut these off since they're in the way). On the front I can just weld a thick steel plate at the top between the tubes and place 2 long studs down there. On the rear I can weld 2 mounting points on that tube in the middle and bend the mounting points on the charger itself straight down. Will be firmly attached like that I think.
And the idea I have for the battery boxes is just some corner profiles of 3 mm thick steel welded together with some mounting points on there. There'll also be mounting points on the frame itself and they'll be firmly attached like that. I'm not really sure yet if it'll actually be like this but I think it will.
Posted on 29 April 2014 at 11:31 pm (CET)
Some progress with the battery boxes again. Added EPDM rubber between the boxes and the covers, used a hole punch set to easily cut the holes into it.
And everything attached again, also added the cable glands. Wanted to see what it'd look like. The battery boxes are completely water- and dustproof like this.
I also placed them all in the frame for now. I'll have to find a good way to attach the battery boxes firmly onto the frame now. I was thinking to place some aluminium corner profiles around the boxes and make some mounting points on there. But I'm not sure if that can be done. These profiles can only be 1,5 mm thick, otherwise they won't fit in the frame anymore.
And a complete picture of it. Others place very big engines in their frames, I just place some plastic boxes in it.
Think it'll be quite a challenge to properly attach everything.
Posted on 18 April 2014 at 10:46 pm (CET)
This past week I've been busy finally finishing the battery boxes. Went pretty good, the covers are now attached. Just need to tidy them up a bit, spray them and add some EPDM inbetween and then they're really done.
First I sawed some new plates for the covers. The ones I already made didn't really fit anymore since I took apart the battery boxes back then and widened them a bit. I made these a bit bigger now so I could make them perfectly even with the boxes after attaching.
Just like with the clamps I drilled the holes through the covers and clamps to get everything properly aligned.
Then I made the holes in the clamps a bit bigger, added rivet nuts in there and placed rubbers on them. I also still glued those 2 extra pieces in the big battery box so the cover would stay closed on those places as well.
After that I could attach the covers on the battery boxes.
Also filed the covers already so they're even with the battery boxes, looks pretty nice now.
Don't have to do much with these battery boxes anymore now. The next step is finding a way to attach them to the frame.
Posted on 17 April 2014 at 01:25 am (CET)
Category: Website updates
Made some improvements to the website. Was planning to do this earlier but since I wanted to have the website online as quickly as possible I put these things on hold. These are the things that were improved.
- New picture gallery. It looks the same but it works very differently. The old picture gallery was quite slow when scrolling through the pages and I couldn't really find a good alternative. So I made my own, needs way less code and works at least 5 times as fast. The quality of the thumbnails is a lot better as well.
- Thumbnails next to the titles of all posts are actually thumbnails now. Before these were just resized. Loading times are much improved in quick view because of this. I also made these thumbnails as links to the related posts.
- It's now possible to enlarge the images on all pages, not just in the picture gallery.
- Fixed a few small bugs.