Blog
Posted on 5 January 2015 at 01:43 am (CET)
Category: Wiring (12V), Wiring (HV)
Posted on 5 January 2015 at 01:43 am (CET)
Category: Wiring (12V), Wiring (HV)
First off I'd like to wish all readers a happy new year. Hopefully 2015 will be a very good year for all of you.
The first update this year and it already starts good. I was able to completely finish the top case this weekend.
The protective covers were all sprayed black. I did this myself and it actually still turned out pretty nice.
I still want to be able to detach the plates so I bought some connectors again for all of the wires. The top case itself is already waterproof so I don't need waterproof connectors for this. First I put all of the contacts on the wires.
With the connectors on.
Since I made a complete new wire harness I wanted to add some extra safety. I bought a few fuse boxes which all seperate circuits are fused with. Was a lot of work to connect this all but it'll be very nice when it's in use.
The wires between the DC-DC converter, 12V battery and wire harness were also very fun to make exactly to size. The + wire of the DC-DC converter also has a seperate fuse.
Attached everything to the protective cover. Now you know what all the holes I made in it are actually for.
Was quite some work to get everything connected before I could attach the plate but finally it looks very nice now.
DC-DC converter attached and connected.
And another protective cover on there.
The 12V battery I won't connect for now. I did this for a short moment but then I saw that the DC-DC converter actually draws a little power. So I can only connect it once I have the whole battery pack connected so the DC-DC converter can keep the 12V battery charged. That's what I'll be busy with the coming days. Will be a bit more exciting since I won't be working with 12V anymore but 72V.
Posted on 30 December 2014 at 11:52 pm (CET)
Category: Wiring (12V), Wiring (HV)
Posted on 30 December 2014 at 11:52 pm (CET)
Category: Wiring (12V), Wiring (HV)
Just a quick update before the end of the year. I continued with the wiring again. The wire harness itself is pretty much done. Just still had to connect everything at the rear to the controller and in the top case.
On the controller I've done it already, everything's connected there now.
In the top case I removed the protective plate again and made some modifications. The round holes are for cable pass through and some switches. What the bigger holes in the front side are for I'll show you in a few days once the plates are sprayed and everything's on there.
The wires to the top case are also all in there already, just still have to connect them all.
And the thicker high voltage wires for the DC-DC converter are also ready to be connected.
Next year there'll be more updates again. January will be very fun, that's what I can tell already.
Posted on 19 December 2014 at 12:11 am (CET)
Category: Charger, Wiring (12V)
Posted on 19 December 2014 at 12:11 am (CET)
Category: Charger, Wiring (12V)
Past few days I was able to do a bit more again. The charge inlet is all connected now. Just still have to find a way to seal the rubber at the bottom.
I also still continued with the wire harness, there are quite a few wires added again and everything that had to be combined is already soldered.
The wire harness is almost completely done for a test ride now. Just still have to add the wires for the lighting after that. But I'm still waiting on the new wires that I ordered, untill I get them I can't really continue with it.
Posted on 7 December 2014 at 11:43 pm (CET)
Category: Wiring (12V)
Posted on 7 December 2014 at 11:43 pm (CET)
Category: Wiring (12V)
The past 3 weeks I unfortunately didn't have much time to work on the quad bike so not much has happened. But I did make a start already on the wire harness.
First I started with placing the waterproof connectors on all of the wires. A lot of time went into this. I do have a special tool for this but there are quite a lot of wires where I have to crimp the contacts onto.
Here with just the contacts and rubbers on there.
Then I placed the connector enclosures on there.
I've done the same with all of the switches on the gauge plate.
This weekend I could finally start with the wire harness itself. I just found out already that I don't have enough wires and also not enough connectors. So I'll have to wait for that to be able to continue again. But I do already have a few wires done.
Meanwhile I also had to modify the handlebar switch a bit. I saw in the diagram of it that it has to be connected in a different way than the original one I had. The killswitch and horn used the same + wire, that would never work well in my case. So I gave the horn a seperate + wire and I also switched around the wires for the killswitch so the icons will match with what it actually does. Was a bit easier than having to adapt the whole wire harness to this.
The coming days I'll continue with the wire harness again, this is the kind of work that I really like.
Posted on 17 November 2014 at 12:07 am (CET)
Category: General, Wiring (HV)
Posted on 17 November 2014 at 12:07 am (CET)
Category: General, Wiring (HV)
Finally an update again. These past 2 weeks I've definately not just been sitting on my hands. Lets start with the small things.
I've placed the wires for the sensor to the batteries. These are very important wires, because of them I can always see the voltage of the whole battery pack and the capacity is also calculated like this. So that's definately nice to know while driving.
For the looks I bought some new mirrors, these match very well with the carbon mudguards. Looks much better than the standard chrome mirrors. Just have to wait and see how the view is. The only problem is that these don't have an E-marking, so I'll still have to use the chrome mirrors for the road approval test at the RDW.
But the most important is that the top case is pretty much done now. I've made a protective cover out of plastic that fits over the contactors and is closed off all around it. This way it's impossible to still touch anything with live voltage. Mounting points for this are glued in again. The DC-DC converter to convert 72V to 12V still fits very nicely on top of this as well.
But since this is open on the top and has live voltage on certain parts I also had to make a seperate protective cover for this. On the rear I drilled quite some holes so the heat can go out.
Then I was still left with the 12V battery. The plan was to place this as a square block as far as possible to the right but because of all the round shapes in the top case this was just too difficult. So I ended up placing it as an oblong shape in the middle. The sides are covered up again. I left the rest open, I think it looks pretty nice.
This will all still be sprayed black and then I can continue with the wiring again.