Blog / Parts
Today I received the aluminium plate. Also a new front sprocket and some new dust caps. I ordered these for the steering rod end, however these are for the ball joints. Again a delivery with the wrong parts. Oh well, I assume this will be solved as well.
The current steering rod end dust caps are already broken while I haven't even ridden on the quad bike yet. They're not really of great quality.
I already gave the aluminium plate and the steel blocks to my friend, now I have to wait again till they're routed. Could maybe take 2 weeks, hopefully faster. But if it gets done well it's worth the wait.
The front sprocket barely doesn't fit over the motor's axle, the hole will have to be made just a bit bigger. And maybe also remove the threads in the mounting holes, the sprocket will be mounted differently than how it normally is in the Loncin engine anyway so I wouldn't be able to use the thread on the sprocket itself.
Posted on 4 April 2013 at 05:10 pm (CET)
Got something again today, from Belgium this time. It's definately becoming an international quad bike this way.
Blank rear sprocket (530) with 44 teeth. Only still need the holes drilled. My friend who is making the motor mount will also do this so it'll be alright.
I almost have all parts complete now, just a few more small things. And ofcourse the batteries but they should arrive here in 2-3 weeks.
Today I received the BMS (Battery Management System). Had to get this all the way from America since we don't have anything like this here. Or well, only 3-4x more expensive. Pretty quick delivery, bit less than 2 weeks. Also didn't have to pay much tax for import, way less than expected.
The BMS is there to take care of the batteries so you can't under- or overcharge (very important for lithium batteries). The batteries also get balanced while charging so that you can get the maximum capacity out of them for a bit higher range.
Here you can see the whole system. All the small printboards will come on each of the batteries and are connected in series. I ordered a few extra just in case I'd destroy one making a wrong connection.
On bottom left is the head-end board as they call it. The whole loop of battery boards will be connected to this and this one basically manages everything.
In the middle is a sensor that can measure the current, voltage, temperature and some more things. It sends all this information to the display you can see on top right. On this display you can also see the capacity of the batteries.
Head-end board coincidentally fits in the small box that I got with the charger. This was actually meant for the little relais but I can place this in there as well now.
Last week I still got some more parts, will post them here as well since it's all part of the project.
Black cable glands in trade for the wrong gray ones. Rubber insulator caps for the terminals of the controller and motor. Some more cable shoes with different sizes (will still have to order more of the big M6 ones since the batteries also need M6 instead of M10). Orange heat shrink only for color coding on the black cables I received for the charger and DC-DC converter since this is also high voltage.
Then there's still a small charger that can charge one 3.2V lithium battery at a time. I will need this to charge all of the batteries for the first time to get them balanced. The batteries will all be connected in parallel for this. After that the BMS will keep them balanced. Came all the way from Czech Republic, just can't get these things here. This won't be fitted to the quad bike but it does make sure the batteries are immediately ready for use.
Also 2 steel blocks. I will have these routed together with the motor mount so they'll get a bit smaller, sloped and lighter. After that I can get them welded on the rear swing arm and the motor mount will be attached to these blocks.
The plate for the motor mount is also ordered already. It was pretty hard to find the correct size. I again couldn't find it here so I ordered it in Germany.
Today I got a package with a total weight of 18kg, what could it be?
Finally received the motor from LMC Ltd., with some more important parts.
Here's the motor, think it's pretty cool how you can get so much power out of such a small motor. But it's pretty heavy for the size, it weighs 11kg.
And the other parts.
On the left 2 contactors (big relais) to switch positive and negative to the motor, so to be able to drive in reverse. Much bigger than I expected, will have to see where I could best place this.
On top the emergency switch with lock, with a press of the button the 72V towards the controller can be disabled with this. Just in case I can't turn off the controller with 12V (keyswitch/killswitch) if anything goes wrong. Or for safe maintenance. The key is needed to turn it on again.
At the bottom another contactor, this was intended for a different controller at first. The controller I have now already has 2 built in. But to be sure I still kept it in my order. Planning to use this in the middle of the battery pack now so it's a bit safer to work with (36V DC is a lot safer than 72V).
On the right the main fuse with fuse holder. Yet again a problem though, it doesn't fit. The bolts are just a bit too thick, the fuse doesn't fit on it. Comes all the way from England so it'll be hard to send back to get a new one. Will have to see how I'm going to solve this, otherwise I'll just buy a different fuse holder here.
First thing I'll do now is remove the rear swingarm to find out the best way to mount the motor on there (can't get it in without removing since the motor is just a bit too big to fit through the frame). I can only mount the motor on one side so it'll have to be pretty sturdy.
After that I'll have some mounts made for the motor and controller and I can finally start adding things onto the frame and connect all cables. At least up to the batteries since I won't have them yet for another 7 weeks or so.
Posted on 2 March 2013 at 11:34 pm (CET)
Today I received the cable glands from Rebbl. Also still ordered 2 fuses and fuse holders with them for the charger and DC-DC converter.
Only a small mistake again, I asked for black cable glands but I received gray for the little ones. No idea how this happened since the bigger ones are black and they were both in the same package. So I'll have to wait and see again if I can trade these for black ones.
Also started with preparations for the controller enclosure. On the front I shortened it a bit since it was taller than the side parts. Drilled holes to attach everything. Made some cables that will connect to the mesh shield in the orange cables for earthing. Also fitted the cable glands. So this is what it will look like, just have to imagine the orange cables. And there will also be RFI filters on those cables. Then it should be all complete.
Will just still spray the enclosure black, should look at least a bit better then.
Also still have some good news. If all goes well LMC Ltd., where I ordered the motor, should have everything ready for shipping by monday. Might actually get the motor then next week.
The CALB CA60 batteries were also finally ordered, delivery time of approximately 7 weeks now. After that time I should have everything here (if I didn't forget anything) and then I just need to build everything up.