Blog

Posted on 30 December 2014 at 11:52 pm (CET)
Posted on 30 December 2014 at 11:52 pm (CET)

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.

E-Streetquad Controller connected and more wires to top case


E-Streetquad Controller connected and more wires to top case


On the controller I've done it already, everything's connected there now.

E-Streetquad Controller connected and more wires to top case


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.

E-Streetquad Controller connected and more wires to top case


The wires to the top case are also all in there already, just still have to connect them all.

E-Streetquad Controller connected and more wires to top case


E-Streetquad Controller connected and more wires to top case


And the thicker high voltage wires for the DC-DC converter are also ready to be connected.

E-Streetquad Controller connected and more wires to top case


E-Streetquad Controller connected and more wires to top case


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.

E-Streetquad Charge inlet connected and continued with wire harness


E-Streetquad Charge inlet connected and continued with wire harness


E-Streetquad Charge inlet connected and continued with wire harness


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.

E-Streetquad Charge inlet connected and continued with wire harness


E-Streetquad Charge inlet connected and continued with wire harness


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.

E-Streetquad Started on wire harness with waterproof connectors


E-Streetquad Started on wire harness with waterproof connectors


Then I placed the connector enclosures on there.

E-Streetquad Started on wire harness with waterproof connectors


E-Streetquad Started on wire harness with waterproof connectors


I've done the same with all of the switches on the gauge plate.

E-Streetquad Started on wire harness with waterproof connectors


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.

E-Streetquad Started on wire harness with waterproof connectors


E-Streetquad Started on wire harness with waterproof connectors


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.

E-Streetquad Started on wire harness with waterproof connectors


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)

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.

E-Streetquad Protective covers for contactors, DC-DC converter and 12V battery


E-Streetquad Protective covers for contactors, DC-DC converter and 12V battery


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.

E-Streetquad Protective covers for contactors, DC-DC converter and 12V battery


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.

E-Streetquad Protective covers for contactors, DC-DC converter and 12V battery


E-Streetquad Protective covers for contactors, DC-DC converter and 12V battery


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.

E-Streetquad Protective covers for contactors, DC-DC converter and 12V battery


E-Streetquad Protective covers for contactors, DC-DC converter and 12V battery


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.

E-Streetquad Protective covers for contactors, DC-DC converter and 12V battery


This will all still be sprayed black and then I can continue with the wiring again.

Posted on 2 November 2014 at 01:00 am (CET)

The past week I've done a lot of work again. First thing I wanted attached in the top case are the contactors for being able to drive in reverse. This all went well, I just hope that it's strong enough.

I made a whole construction out of plastic where the contactors fit in nicely.

E-Streetquad Contactors for reverse attached in top case and connected


Also made mounting points that I glued into the top case with special glue. With this I have to wait and see if it's strong enough.

E-Streetquad Contactors for reverse attached in top case and connected


The contactors I can easily attach or remove this way. Meanwhile I've also connected the last few wires for the propulsion. The smaller black wires are just for earthing of the shielding in the orange wires, just still have to isolate these so they can't come in touch with the contactors.

E-Streetquad Contactors for reverse attached in top case and connected


I was worried that it wouldn't look so good on the outside of the top case but it doesn't look too bad. As you can see I ended up using cable glands again instead of those rubbers. The wires stay in place much better like this and the top case is still waterproof.

E-Streetquad Contactors for reverse attached in top case and connected


E-Streetquad Contactors for reverse attached in top case and connected


E-Streetquad Contactors for reverse attached in top case and connected


I've also tried with the rear fender on it already and you don't notice the wires as much then. I just forgot to take a picture of this and the fender is also off again. So I'll show that later.

The plan now is to make some shielding in the top case so the contactors won't be visible anymore and untouchable. But that will take a while again to finish.