Begin the wiring up

  Charge plug fits nicely into fuel cap using standard Plumbing fixings, The cap hinges and makes a nice air/weather tight seal. For interest sake the tank's from a 1972/3 Honda CB 350 

4 "idiot" lights mounted in tank, from top, Blue-High Beam, Orange-Indicator, Green-On, Red-Charging. I have a micro switch which will open circuit the ignition circuit while charging. 

Bottom tray which will be riveted on and sealed with a silicon sealer as this area needs to be water tight to house the controller.   

Ear rings! no LED indicators 

 Office coming together

Perspex mounting board for the beginning of wiring, I hope it's as easy as the leg bone connects to the hip bone!

I

Just showing the earthing common connector and earthing wires to the frame.

The Big Red Button

 Although I have a kill switch on the handle bar switch block I'm still having the big red kill button. The back cover plate has been cut from an old metal storage shelf , it also has the ignition on/off switch fuse and the 8g inertia switch mounted on the other side  

 Here is the rear view of the mounting plate showing the main isolator "Big Red Button" the 8 to 20g inertia switch, ignition switch and fuse holder. The "On" cct. has it's own 12 volt power supply operating the main contractor for the traction cct.

Basic cct diagram

 Rear of tank filled and sanded tread for primers

Not much time but new stuff done

                                     Potbox, Hall effect and main contactor installed

                                                    Cable from original throttle

                                       Front disc calliper recon and installed

                          Headlight, original reinstalled, to damm dear for a new one

                           rear brake now cable operated with shortened clutch cable

                             Fuel tank bottom cut out for weather proofing electrical gear

                                 First application of fibre glass to Finnish off end

                                           Looking up into cutaway tank on bike

                       Speedo and custom bracket from GN250 1982 Suzuki, GN was the single cylinder

Quick update battery box and forward control

Bit rushed will give more detail soon, Cheers

Oh SH...T

After last night's electric vehicle club meeting I found a member who's converted a Lotus Elise to electric. He had laid down 25 of his 40+ Lithium batteries, to find out 12 of the 25, in the laid down position failed after a short time - nearly 50%. It appears the electrolyte can't come in contact with all the plates in the battery.  So I have nearly finished my battery frame, which has all 16 batteries laying down. So out with the grinder and chop! chop! chop! 

So the "dummy" packs for the batteries are no good, I'll just use a measuring tape

Again I can use the original engine mountings for the battery pack

There! That will have them all standing up like little soldiers. There was a good picture for the electrolyte and how it could not contact all the lithium "plates" when the cell was laid flat, I'll try and get this.

\

Spex

Someone has asked for a specification / parts list so here it is Item	Description	Cost Au $	Weight  Kgs	Size
Alltrax  AXE4834 DC Motor Controller	24-48V 300A, for Series and PM motors	$415	2.9	195 x 146 x 71
Motenergy ME0708	48V Brushless DC Motor, 6-12kW	450	15	149 D x150
Thunder Sky LFP060AHA	LiFePO4 Cell 3.2V 60Ah Pack of 16	1360	34.5	61 x 114 x 203  915
battery charger Kingpan KP4810EL(600W)	LiFePO4 Cell 3.2V 100Ah 48V 10A switchmode	225	3	220x120x70
HWZ Series DC/DC Converter	48V to 13.5V 25A	149	2	200 x 140 x 72
BMS-CM160-V6	LFP100AH BMS Cell Module x 15	195	0.225	n/a
BMS-MCU-EV2	Single channel Master Unit for Evs	179	2	170 x 100 x 75
ZJW200A Contactor	200A rated contacts, 12V coil	49	0.9	n/a
Precharge Resistor	1kohm 10W resistor with 3/8in ring terminals	4.5	0.05	n/a
ANN Fuse, 400A	For low voltage circuits (72VDC max)	13.5	0.1	n/a
Inertia Switch	Vehicle crash sensor, 8-14G	22.5	0.06	n/a
250A Emergency Disconnect Switch	Big Red Button, 250A continuous	26.5	0.5	n/a
Power Cable, 25mm² Orange	Double insulated, sold by the metre x 3mtrs	19.5	0.9	n/a
		$3,109	62.135

Dummy battery packs

Photos showing mock ups of the battery pack size required to make sure all will fit.

Total of 16 60 amp hour lithium batteries stacked on the their side, each individual battery has the dimensions 203mm x 114mm x 61mm

This shows there will be 3 stacks arranged vertically. two stacks will have 6 cells and the smaller stack at the back will have 4 cells 

The foam block at the base shows the size of the Altrax controller