Posted on 13 March 2015 at 11:16 pm (CET)
Very good news today, the quad bike is finally completely built up. You still have to wait to see what it looks like right now though, I'll show this on Sunday. Tomorrow I'll probably go out for the last test ride before I go to the RDW with it. I'll make another video again. :)
But as promised I'll already show you a few little details. ;)
The quad bike has really become very beautiful, can hardly wait to share it with you all. Just a little more patience. :)
Posted on 10 March 2015 at 12:50 am (CET)
Just a quick update after the weekend. Made the quad bike a bit lighter for now, the wheels had to go off. You might be wondering why but you'll see within a few days. ;)
Placed the last few wire hoses around the orange wires. Looks pretty nice now, it just makes the wires even more stiff. But it's not really a problem. As you might be able to see the motor is running here. I'm busy seating the brushes so I can see if this will lower the temperature. For this I'm letting the motor run at 1000 RPM for about 12 hours. I'm just at 7 hours now so it'll still take a while.
Unfortunately I'll have to modify the fenders a bit in a few places. Here where the 2 wires cross eachother I had to bend the fender a bit so they still fit. I also expect that I have to modify the rear mudguard a bit since the wires to the motor are in place there.
I'm really working on the last few things now before the fenders can go on. This coming Saturday I'll probably go testing for the last time and I hope to have the quad bike completely finished by then. I'm really curious myself what it'll look like. :) To make it a bit more fun for you as well I'll only show this all after the testing. ;) I might show a few little things this Friday but the pictures of the end result will come some time this weekend.
Posted on 1 March 2015 at 12:58 pm (CET)
Yesterday I went testing for the second time. First I went to a boatyard's parking lot nearby. Usually you can drive all the way around but since the water was high this unfortunately wasn't possible now. But the asphalt also wasn't as good as I thought, because of this it turned out to be a good test to check if any bolts or nuts would still come loose though. ;)
I rode around here for a while and it was very fun again. Could really notice that I had a lot more power now than during the last test. Acceleration was much quicker now. But I still don't think I had the full power. The highest I've seen is 315 A while everything is set up for 400 A. But I also couldn't keep looking at the gauge the whole time since I had to keep looking where I was riding. For the next test I'll just place the camera in front of it, then I can at least see everything at home.
But everything went well, nothing came loose anymore and nothing broke either. The temperature sensor in the motor is working fine as well. Only problem was that the motor got pretty warm quickly and I had to let it cool off a few times. It's probably because the brushes aren't properly seated yet so I'll just have to wait and see. On the parking lot I also couldn't really reach a high speed and was really only accelerating and braking the whole time. So I left there and since I couldn't resist I did a few quick runs on the road. :)
The real fun started here since this was actually the first time at higher speed. The quad bike again did very well here, it all felt great and it just kept accelerating nicely. It definately has more than enough power. First I tested at low power (Eco mode) so the motor wouldn't get so warm right away. Accelerates less quickly then but on that road I was able to get up to 75 km/h (46 mph).
But I knew that it could do more so after that I tested again but this time at high power (Sport mode). I reached 75 km/h (46 mph) very quickly now and was able to get a maximum speed of 82,6 km/h (51 mph). That was pretty much the goal of this test, getting above 80 km/h (50 mph) for the first time. And that has also succeeded. :)
In total I rode almost 10 km (6 miles) again, so the same as the last test. Only the ride time was a bit less this time since the quad bike was much faster now. ;) Only thing I need to keep an eye on for now is the temperature of the motor, at the moment this is getting a bit too high.
Ofcourse I brought the cameras with me again and made a video again. Think you can see really good that the quad bike has more power now. :)
This coming week I'll order the new tyres so the Chinese tyres can go off. And I'll also completely finish the quad bike by adding the fenders on. I'll probably test once more before I go the RDW but for now it's all looking good. If I don't run into any problems anymore during the next test then I also don't really expect any problems at the RDW. It'll definately be very exciting.
I continued again solving the problems that I still had.
I was able to place the temperature sensor of Trailtech in the motor, attached it with JB Weld, will be stuck on there forever. Also tested it already and it seems to work well. Will find out on the next test ride if it really works properly.
I tightened all of the nuts in the motor again and added Loctite inbetween. Then I placed another nut on all of the nuts that are holding the connection points of the motor and the carbon brushes, again with Loctite. I don't really expect this to come loose again. Also lengthened the wires for the temperature sensor.
After that I placed the motor back on the quad bike again and connected the orange wires in a better way. They have a lot more play now with suspension travel of the rear swingarm, should be almost no pressure anymore on the connection points of the motor.
I noticed that there were big sparks between the contacts of the small 12 V relays when disengaging the contactors. I used some diodes for this, the contactors open a bit slower now but at least there are no more sparks anymore in the relays. Don't want to keep replacing the relays when they break.
Also added a capacitor and resistor so the contactor between the battery packs uses less power, now it doesn't get so warm anymore.
On the contactors for forward and reverse I only used the diodes since these won't be engaged for such a long time, heat won't be an issue here.
I've now fixed all of the problems that I ran into. Hopefully there won't be more coming soon since I really want to go the RDW this coming month for the road approval test. But before I go there I want to test at least once more. Tomorrow the weather would be nice and the quad bike is rideable again so I already charged the batteries a bit. ;)
Apparently I hadn't found all problems yet that arised after the test ride. I'm glad I found them now though or the next test ride probably wouldn't have gone so well. For pretty much all of the problems I had to buy these few things.
A few bolts of the front swingarms had come loose. I didn't put any Loctite on them just yet since I wasn't sure how tight they should be. I suddenly saw that there was some space inbetween, that's never good. So I loosened them all, put some Loctite inbetween and tightened them again. Should not come loose anymore now unless I really want to myself.
On the rear something also came loose, the 2 big nuts that keep the sprocket adapter stuck to the rear axle. Because of this the sprocket adapter was ale to move freely on the axle. I did already tighten this with blue Loctite inbetween but apparently that was not strong enough for the forces it has to endure. Also noticed that there was some play between the sprocket adapter and the axle. So I first used Loctite Quick Metal to fill up the space. Then I used red Loctite again to tighten the nuts. This should also not come loose anymore.
After that I continued again with the orange wire hoses. It's pretty hard with these thicker wires, especially the bends. It also still barely fits between the mounts.
On the side of the controller I already placed the RFI filters to reduce noise, also neccessary again for the road approval test at the RDW.
While I was busy with the wire hoses on the wires that go to the motor I suddenly discovered a very big problem. I noticed that there was some play on the connection points of the motor. I immediately took off the protective cover to see what was going on. To my surprise I saw that literally all of the nuts inside were loose. So the connections to the carbon brushes were also all loose. This is something that should never happen, If I would've pushed full power through the motor something would've certainly gone wrong. You can't really see it on the picture but really all of these nuts were loose.
The cause of this is very simple, it's because of the stiff orange wires that didn't have enough space during suspension travel of the rear swingarm. Will have to completely change this because like this there will be too much pressure on the connection points of the motor. I'm first trying to place the wires in a straighter line to the connection points and not all the way through the frame anymore. I will also tighten all of the nuts with Loctite so these hopefully never come loose again.
But ofcourse I couldn't easily reach it anymore so unfortunately I had to take the motor off the quad bike once again. Thankfully this is still pretty easy to do, I really only have to jack it up and remove the suspension. Can just take out the motor together with the motor plate after that.
Since I have the motor out now anyway I also checked if I could replace the temperature sensor with the one from Trailtech. That way I can be sure that I get to see the right temperature on my display. I'm just not really sure yet how I'm going to attach it and if I can even use this sensor this way. Will have to contact the supplier of the motor again for this.
I hope that these were the last few problems for now. It's not really fun to discover these things knowing that the quad bike is almost all finished. But on the other hand it's definately better to see it now than when it's too late.