Electric Pocket Bike 1000w

About a year ago i had decided to start converting my old broken noisy chinese thing into an electric mini moto. I have had experience with motors and electronics in other projects before; chinese electric dirt bike, electric bike, electric scooter etc...

And a year later here i am showing you how i have built this monster from a rubble. It had been sitting in my garage with the rolling chasis and the motor attached, nothing else had been done. I had no money to buy a crontroller and had not had a chance to add or modify it.

These are the steps and proccesses i took to build my bike:

First of all i dug out the mini moto with the 1000w motor attached. the motor is 36v which is the same as the system i am running. I will hope to make it to 48v to get more speed.




I then got all the materials together to begin to make the circuit.
1. 2 batteries of 12v 12ah
2. 1 battery of 12v 7ah
3. Uni-8 36v 100amp controller from http://www.4qd.co.uk
4. Magura throttle and matching grip
5. Key switch
6. Battery level indicator of 7 LED's



I then decided to make a battery pack out of the three batteries to make it easier to charge and put the bike together. :P I also attached the LED battery indicator.


This is what the circuit/setup looked like before attaching it to the bike.




This is the final bike;



Specifications:

Owner: Jake Saunders
Location: Wellington, NZ
Email: jake27surf@hotmail.com
Vehicle: chinese petrol mini moto
Motor: 36v 1000w unite motor
Controller: 4qd uni-8 100amps 36v
Batteries: 1 Chinese 12v 7ah 2 Maplin 12v 12ah
System Voltage: 36v and i want to up it to 48v
Top Speed: 20-25mph --- around 30 - 35kmh
Range: Around 5-8 km
Conversion Time: 2 days on and off working on it
Conversion Cost: 250$ or €200 with most of the products coming from the USA.



Thanks for looking. If you have any questions feel free to email me.

Decided On Batteries.

So I have decided to go with a different battery package.. Since the old one only had balancers for each single battery, and did not interfere with the charger or stopping one from receiving too much charge. Thus I am going to buy this package which includes bms too:http://elitepowersolutions.com/products/product_info.php?cPath=27_29&products_id=111

Mainly because they come with a proper bms. But also because they are around 7lbs lighter which is pretty crucial. Another advantage with these is that they have a 3c discharge rate continuous, compared to the others 2C. They have the same kwh and voltage ranges etc. The weight difference should really be helpful. I'll probably be doing some ordering and work on the bike this weekend. Need some wire etc.

The website says this:

Advantage of GBS 2nd Generation Li-ion Batteries Compared To Thunder Sky Batteries:

- 10% higher energy density by weight and by volume;
- Superior safety performance due to patented new safety valve and pressure cap designs;
- Batteries do not explode or catch fire when batteries are shorted or punctuated resulting in internal shorts;
- More robust connection due to new electrode terminal design using four rivets or four screws per terminal; Prevent loose connections caused by vibration;
- Reduced impedance due to improved electrode terminal design;
- Improved cycle life;
- New cell structure better facilitates BMS integration and battery pack formation, and improves air circulation.

Jake

Brake Mount Done. Fitted!

The bike is now ROLLING!!!
Today i got the bike into a rolling chassis and tested it downhill. It has a tighter turning radius with the new forks and smaller wheels. The rear suspension does not need to be changed because the angle is fine. Both forks and rear suspension are working well. Tested the brake mount pretty hard. Some really hard and strong force stopping. Mount has stayed firm and not moved/buckled/bent. I am very proud of the mount and how successful it is! :)
Here are some pictures of the mount and rolling chassis and the bike with the tank on  :o  i think it looks great!!!

EDIT: I mounted the brake mount at that angle because there was a mount for the suspension in the way, so it could not be at the same angle kelly stated. I find this angle pretty effective :mrgreen:

Motorbike update. Hub Motor + Forks Fitted

I spent a couple hours in the garage this after noon and accomplished quite a bit. I got the hub motor fitted to the swingarm with relative ease. Ill be fitting the brake tommorow as i need to get some bolts for it and the hub motor mounts. I also fitted the forks off the pitbike i got, which are nearly finished. It looks like i probably need to get a longer rear suspension, as its sitting a little low. What do you think?

Thanks.

Order Arrived! Motorbike

Here are some pictures of the goodies:

Thanks.

Change In Order! Motorbike

I have sent this email to kelly controllers:
Hi,
I have been thinking, and since the order has yet to be shipped. Could I change the Keb controller i currently have for this: http://www.newkellycontroller.com/product_info.php?cPath=24&products_id=564 .
Because the controller i currently have ordered does not fit my needs. Since the price is different could I *Not have the charger. So like this:
- 1 x KEB48300 150A 48V 3KW -$209.00
+ KEB48600 300A 48V 6KW +$349.0
= $149 more
So Minus the charger aswell!!
- 1 x F4815-48V/15A Charger -$199.00
That equals to $59 + which can be refunded?
So the order comes to:

1 x Low Cost Compact Assembly (KEB/KBL/PM ) $99.00
1 x Kelly 48Volt Charge Meter $19.00
2 x Throttle Hall 0-5V Twist Grip(WUXING) $38.00
1 x Optional Waterproof $38.00
1 x KEB48600 300A 48V 6KW $349.00
1 x HWZ Series DC/DC Convertor 48V to 12V 300W $129.00
1 x Hub Motor 48V3KW (High Speed)(disc-brake) $399.00
1 x Kit for Disc-brake Motor(big) $99.00
1 x Motor Tyre (13-inch motor special) with Vacuum births $79.00




$59 USD to be refunded!

Sub-Total: $1,249.00
Table Rate (Best Way):
Total:
$277.00
$1526.00
That is what i would like for my order! If this cannot happen. Cancel my order and i will reorder again!
Thank you
Jake

I will be rethinking about what im going to do with the batteries!
Thanks,
Jake

Update On Motorbike

Yesterday i also decided to order some parts from evworks;

-Power connector, 600V 175A 6 $37.92
-Heatshrink - 13mm Black 2 $6.90
-Copper cable lug, 16-8 14 $12.04
-Emergency Stop Switch Low power 1 $10.00
Subtotal: $66.86
P & P (Registered International Air Mail): $27.00
TOTAL: $93.86 AUD --> NZD $120

So i just have to arrange the payment and that will be on its way. I was going to order 12 meter of 16mm2 orange wire, but I think I'm just going to get that locally.
Once the parts arrive ill take lots of pictures!!!

To Do List:
- disassemble bike for sanding/painting
- primer it
- spray... thinking of black frame, green tank/fenders
- buy batteries
- buy wire
- fit new disc brake pads
- maybe look for new front forks.. at the moment they are real rusty and there's a leaking fork seal
- paint tank/fenders
- make battery frame
- maybe adapt swingarm for hub motor
- make wiring harness
- buy plastic or make moulds for fibreglass battery cover
- get the bike registered for road use
- wof
- electric motorcycle completed

Got quite a few things to do!

The Start Of The Suzuki GT50 Conversion

The bike is going to be converted from 49cc petrol engine to a 3Kw 48v system. The hub motor is going to be the Kelly controllers 3Kw high speed motor. Controller 48v 150A 3kw Kelly Controller. And i am wanting to try and integrate the charger onboard this smallish frame. Soon I'll be able to ride the electric motorbike to school everyday. A couple months ago (more like 2 months ago) I bought a Suzuki GN250, which i was going to use to commute, but after a while of riding it, i found it to be boring. Sold it for NZ$2300. I have been dying to start another project, since i literally just moved to New Zealand. Ok, well lets get onto the project lol.

I'm starting off with a Suzuki GT50, working ICE etc, a lil bit of rust. Not bad for a bike from 1979 :) Bought for NZ$286 ....

Engine coming out:

ENGINE IS OUT!!!!!

At the moment the rego and wof has lapsed out as it has been in storage, so will need to be re registered which will cost a bit :(

So far i have bought this from Kelly Controllers, which I am anxiously waiting to arrive;

Kelly 48Volt Charge Meter                    $19.00   

Throttle Hall 0-5V Twist Grip(WUXING)                $38.00

Optional Waterproof                        $38.00       

F4815-48V/15A Charger                        $199.00   

HWZ Series DC/DC Convertor 48V to 12V 300W            $129.00   

Hub Motor 48V3KW (High Speed)(disc-brake)            $399.00   

Kit for Disc-brake Motor(big)                    $99.00   

Motor Tyre (13-inch motor special) with Vacuum births        $79.00   

KEB48300 150A 48V 3KW                    $209.00   

Low Cost Compact Assembly (KEB/KBL/PM )            $99.00                                                         

                             Sub-Total: $1,308.00 + 277 -----> NZ $2274

Says the high speed motor is rated at 76kmh no load. so should get around 50-70kmh average.

I sold my GN250 for NZ$2300. Giving me enough to buy this. At the moment i am saving up for all the accessories and wire and connectors, which comes to around NZ$150. Once bought, I need to save up yet again to purchase batteries, which accumulates to:

BATTERIES---Scooterparts.co.nz: B-009

4X 12-Volt/24AH  ==============$ 164    Each

Dimensions (mm):

L165xW174xH125          Total: NZ$656

I am going to try to weld a frame around the batteries, using bolts to secure the battery box to the old engine mounts. Making the batteries detachable if needed to be in future, replacement of batteries maybe? I have the idea very very clear in my head and have done a few concepts on paper. I need to make the final design and then I'll post that. I will update on this thread when i do something with the bike, I so far have cleaned up the frame:

Everything will need to be taken off and be sanded down. I.e Rust. Then a coat of primer to be added plus a green sprayed tank etc. Then to get it road legal and more rider comfortable i am going to buy new set of lights all round bike. I am going to be making the wiring harness myself which i will hopefully get right.. lol

No need to ask why i didn't use an etek or similar motor. I have debated that already. I just want to try something different and new, could use creating/converting/selling ev's as my career, and will always need to try new things. :) I really like the bike... It's so slim haha.

Regular updates :)

New ideas would be great and all comments appreciated. thanks