Blog / General
Seeing as a few things have broken during the test ride I've already had to do some repairs. The most important is the DC-DC converter. Ofcourse it was just out of warranty, already bought it a bit longer than 2 years ago so getting it replaced wasn't possible anymore. But I already wasn't satisfied with it since the output voltage was too low (11,9 V). So I bought a different one now, a Traco Power TEP 150. Same power, bigger input range, better isolated and an adjustable output voltage. Unfortunately it was a bit more expensive but for this price I don't think there's a better one. One more difference, it's a lot smaller.
A fusebox also broke because of the heavy 12 V battery I placed in the top case during the test ride.
Replaced it and lengthened the wires for the new DC-DC converter.
And here it's all connected. It also has the option to turn it on and off with a 12 V signal but for now I'll leave it always on.
Then something I forgot about. Before the test ride I still wrapped the whole wire harness with wire hoses. Quite a lot of work with so many wires coming together.
After that I put tape all around it.
And placed it back again. Think it looks pretty nice like this.
Currently working on putting wire hoses on all of the orange wires as well. It's for added safety and probably necessary again for the road approval test at the RDW.
The only 2 problems I still have right now are a contactor that's getting quite warm and not getting the temperature sensor in the motor to work with my Trailtech display. For this sensor I still have to contact Trailtech to see if there's a way to calibrate.
As for the contactor I've already contacted the supplier and for now they say that this is normal. Just still have to give them the complete part number so they can confirm it. But most likely it's working just fine, I just still think it's getting too warm myself. Still have to find a solution for this so it gets less warm. It now goes up to about 51,5 degrees celcius with an opened enclosure. With the enclosure closed it'll probably go up to about 70-80 degrees celcius. For the contactor itself this might not be a problem but for the other components that I've placed in the same enclosure it might.
That's about it again. Hopefully I can solve these last few things quickly so I can already make the second test ride at real full power very soon.
Posted on 31 January 2015 at 09:51 pm (CET)
Posted on 25 January 2015 at 11:46 pm (CET)
Since I really couldn't wait anymore I made some more space here to be able to test for a bit. Can't really turn or anything so it's just a forward and reverse test. But as you can see it's all working great. It's set to half power now and already wants to accelerate pretty quickly, just need some more space.
Hopefully I can have a real test ride outside and at full power very soon. It's all up to the weather now.
Posted on 24 January 2015 at 11:56 pm (CET)
Thanks to the snow I wasn't able to have a test ride today. Will probably still be here tomorrow as well so it'll have to wait till next week. Hopefully the weather will be better then. The quad bike is definately ready for it.
The wheels are aligned.
Meanwhile I also connected all of the lights. Worked perfectly right away. First I had only connected the brake and turn signal lights for the test ride.
I just noticed that the turn signal lights stay on weakly while flashing. Don't think it'll give any problems for the road approval test but I don't think it should be like this. Normally they should go out completely. It's a new turn signal relay so that can't be the problem.
Since the test ride couldn't go on I also connected the rest of the lights and the horn.
And the headlights. Right is low beam and left is high beam, both in combination with running lights. Just like original, will leave it like that for now for the road approval test. Daytime running light is also connected but didn't take a picture of it. It's nothing special, will also be changed after the road approval test.
This coming week I will tidy everything up and maybe even add the fenders already. For the rest it's just waiting for better weather.
Past few days I've been closing all of the battery boxes and they're attached to the frame as well now. They can't go anywhere anymore, can't get any movement in them at all. To be sure I still added some sealant inbetween the rubber and the boxes so they're completely waterproof. Even though it's all a bit thicker because of the few coats of paint on them it thankfully all still fits pretty good.
Now I could attach the footrests, nerfbar and heelguards again.
Then I tightened the nets in them again and placed the heelguards.
Starting to look like a real quad bike again. This is what it looks like right now.
Meanwhile I still added the extra relay. Enabling and disabling the charge process works perfectly now.
The only thing that's actually left now is aligning the wheels and adding the saddle. Then I can finally make a test ride with it. Think this will happen on Saturday if the weather cooperates a little.