My eZuma project (Elektra)

Discussion in 'Electric Motorcycles' started by MJSfoto1956, Sep 16, 2018.

  1. Bt10

    Bt10 Long timer

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    Newb question, but how much extra $ would they have charged to make quality, or some other brand to be made quality? Would you have been $ ahead to just buy the cells?
    #61
  2. MJSfoto1956

    MJSfoto1956 Been here awhile

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    That is a very good question. When the dust settles I'll let you know. Might be a wash. Notwithstanding, I wanted to learn.

    M
    #62
  3. MJSfoto1956

    MJSfoto1956 Been here awhile

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    While I continue to ponder the "weld vs. solder" debate, in the interim I have started to wire everything up on my test bench to see how it all works together. Pretty much fired up the first time I flicked the switch, yay!

    Test Bench Components:
    • 2000W QS 260 hub motor
    • 72V 20s17p AliExpress Li-ion battery pack
    • PowerVelocity 20kW controller + Bluetooth app
    • 125A circuit breaker
    • 10A circuit breaker
    • 2A circuit breaker
    • ZEVA Smart Precharger
    • Tyco EV200 Contactor
    • Bussmann 2P Miniature Distribution Block
    • 2AWG and 4AWG marine cable
    • Wuxing half-twist throttle
    Test Bench.1600.jpg
    #63
  4. MJSfoto1956

    MJSfoto1956 Been here awhile

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    Haven't posted in a while. Been working on rebuilding/improving the battery. First a quick note showing what is "less than ideal" about the battery pack I purchased.

    20s17p AliExpress Battery Pack IMG_6806.1200.jpg

    With that out of the way, the past few weeks I have been rebuilding the battery to make it "acceptable". Here is the design I am following:

    tinned braided wire IMG_6807.v9.1200.jpg

    Next up. My progress.
    #64
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  5. MJSfoto1956

    MJSfoto1956 Been here awhile

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    So here is the progress I have been making:

    IMG_6853.1200.jpg

    IMG_6856.1200.jpg

    IMG_6857.1200.jpg

    IMG_6860.1200.jpg
    #65
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  6. MJSfoto1956

    MJSfoto1956 Been here awhile

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    Finished the bottom serial connectors as well as the polycarbonate ventilation spacers. Almost done now with the battery rehab. Just waiting on a 300A BMS and final soldering of the copper bus bars.

    IMG_6874.1280.jpg

    IMG_6874.1280b.jpg

    IMG_6883.1280.jpg
    #66
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  7. MJSfoto1956

    MJSfoto1956 Been here awhile

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    Making some slow-but-sure progress.

    My Battery cabling.v3.1280.jpg

    IMG_6989.1280.jpg
    #67
  8. MJSfoto1956

    MJSfoto1956 Been here awhile

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    Just got back from two weeks of business travel. Added some finishing touches to the 6AWG power harness. Still waiting on some brass parts from China to (mechanically) attach this puppy to the BMS/battery. Hoping the parts will arrive this week.

    IMG_7312.1280.jpg
    #68
  9. MJSfoto1956

    MJSfoto1956 Been here awhile

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    So my plans have been dashed a bit by the Massachusetts RMV. I went to get my moped sticker the other day as the motor is just 2000W or about 3hp. When I got to the counter they said they could not give me a moped sticker since the previous owner had already registered it as a motorcycle. And once registered as a motorcycle it had to continue to be registered as a motorcycle. Basically, if I want to ride this bike on any road here in Massachusetts, I'm going to have to install a "real" motor in it. So I just ordered a 13" V4 8000W hub motor from QSmotor and new Pirelli Diablo 150/70-13 rear tire from Revzilla. Not sure how I'll pay for it, so it all went on the card. The motor should arrive within the next 4 weeks as they are fabricating the windings to my specifications for the hilly terrain we have around here (95kph real-world top speed with the 150/70-13 rear tire). Here's the new updated Phase 1 layout:

    NESE Modules 20p pack.v7d.1680.jpg
    #69
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  10. MJSfoto1956

    MJSfoto1956 Been here awhile

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    my overly-engineered busbar:

    busbar detail IMG_7834.1280.jpg
    #70
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  11. MJSfoto1956

    MJSfoto1956 Been here awhile

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    ...and how it looks spot welded to the pack.
    Notice that the standoffs are to mechanically mount the BMS to the negative copper busbar without cabling.

    IMG_7841 (1).1280.jpg
    #71
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  12. ctromley

    ctromley Long timer

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    Gotta say, you deserve kudos for documenting this. I know how much effort it takes, and how much more detail you could add even beyond this if only there was infinite time. I would have killed for this kind of presentation when I was learning about how EVs work.

    EV noobs take note - study each post and photo in this thread. There's more here than you think. Keep coming back. This thread should be required reading for anyone wanting an accelerated way to get as much understanding of EVs as they think they'll have to give up from their ICE knowledge.

    Great Stuff!
    #72
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  13. MJSfoto1956

    MJSfoto1956 Been here awhile

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    Big shout-out to RevZilla who shipped this Pirelli Diablo 150/70-13 scooter tire in just two days -- with free shipping and the best price I found on the web. Man, this is going to be epic when the V4 QSmotor arrives.

    Note: I'm comparing the existing 120/70-12 front tire (same size as the current rear) to the future 150/70-13 rear tire as I don't have anything mounted on the rear at the moment.

    IMG_7851.jpg
    #73
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  14. MJSfoto1956

    MJSfoto1956 Been here awhile

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    Well I bit the bullet and ordered a V4 QSmotor.

    I told them about my use-case (very hilly region, 130kg bike weight, 72V @ 57Ah, 150/70-13 rear tire) and they suggested a winding that would provide 95kph real-world top speed.

    They started fabricating it yesterday. Here's the receipt:

    QSinvoice.1200.jpg
    #74
  15. MJSfoto1956

    MJSfoto1956 Been here awhile

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    To give you an idea of what I'm working towards, the following sketch captures the overall "look and feel" of my future eZuma.

    P.S. the Chinese characters more or less are meant to mean "Ride the Electric Red Dragon" (if I have the translation not quite right, I would appreciate any refinements from those who are actually fluent in Chinese. But note that I like the implied double entendre of "voltage = ring ride" implying "riding" an electric red dragon)

    Stage 3 _IMG4706_DxO.1280.jpg
    #75
  16. MJSfoto1956

    MJSfoto1956 Been here awhile

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    Got a lot done in the last 24hrs:
    • roughed out a new semi-clear polycarbonate battery box to protect the new battery
    • removed the old (rusting) battery box
    • test fitted the new battery box into the space vacated by the old battery box
    Here are some before and afters:

    IMG_7854.1280.jpg

    IMG_7855.1280.jpg
    #76
  17. MJSfoto1956

    MJSfoto1956 Been here awhile

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    Stage 4: gut the innards to make room for the new motor, controller, electrics, and battery/

    Stage 4 _IMG4706_DxO.1280.jpg

    I wonder what I can get on Craigslist for a 90% complete 2000W 72V scooter conversion "kit" including throttle, swingarm, motor, tire, brake caliper and rotor, wiring, and controller (not going to include the batteries as I have a use for them). Does $200 sound right? Thoughts?
    #77
  18. MJSfoto1956

    MJSfoto1956 Been here awhile

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    Brand new QSmotor V4 8000W 13", built to my specs and just completed. Set to arrive from China in the next week.

    13inch 8000W Motor 2019051001.jpg

    13inch 8000W Motor 2019051002.jpg

    13inch 8000W Motor 2019051003.jpg
    #78
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  19. MJSfoto1956

    MJSfoto1956 Been here awhile

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    I'm thinking I will paint the exposed "naked" parts of the hub motor bright yellow. Thoughts?

    13inch 8000W Motor 2019051002.800.jpg
    #79
  20. wheresbaoskee

    wheresbaoskee Perpendicular to Everything

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    An accent color on the wheel looks great in that pic, but not so much yellow against red. - imnsho. Of course I might have missed if you mentioned repainting the body panels earlier in the thread.
    #80