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Thread: e-cruiser version 2.5 upgrade - build thread

              
   
   
  1. #1
    Senior Member Hugues's Avatar
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    Cool e-cruiser version 2.5 upgrade - build thread

    Went for a nice ride today, but temperature is not getting much over 12-15C so the season seems to be coming to an end. So it will be time to bring the bike into the shop for some upgrades. Not a major upgrade this time like last winter (belt and batteries) but a lot of cosmetic work with my 3D printers.

    Here's what i'm planning to do this winter:

    - Design and 3D print a new headlight. Never quite liked the one i have. Maybe something like this could be cool.

    - Design and 3D print new side covers. I would like to replace the 2 disks i have on each side of the bike and make up some kind of air intake or outake, inspired by this cool car here

    - Reprint my dashboard with my SLS printer

    - Move up my foot pegs, they're too low, my boots are getting worn out, LOL. The place where they bolt on the frame cannot be changed, so i have to design an external bracket, i'll try to print it with my SLS printer out of polyamide-carbon. It's very stiff and has a nice slight flex.

    - Design and print a bracket for my new contactor

    - Design and print some "skins" on my front fork and swingarm, printed in black, and i will cover the bike first with a burnt orange vinyl film. Let's see where i go with this.

    - I have yet to receive the copper filled PLA i bought on kickstarter. When i get it, i need to design and print a heatsink for my motor.

    - Might try to add some fins on each side of the front body panels.

    - Designing and 3d printing some kind of spoiler on my rear fender.

    - Check all battery connections and wiring

    - Repaint body work and rear fender, a bit darker but not completely black.

    That's gonna be another busy winter, cool, i like this.

    I'll update this thread when i have something to show.
    Last edited by Hugues; 30 May 2016 at 2038.
    Regards from Switzerland
    My 2.5 Upgrade Thread

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    Senior Member Athlon's Avatar
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    PLA filled heatsink don't sonud good to me .

    Even with copper inside plastic still a very poor heat conductor,

    also I think you can end up with meted heatsink and some copper ending up inside the motor or on some wire

  3. #3
    Senior Member Hugues's Avatar
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    Quote Originally Posted by Athlon View Post
    PLA filled heatsink don't sonud good to me .

    Even with copper inside plastic still a very poor heat conductor,

    also I think you can end up with meted heatsink and some copper ending up inside the motor or on some wire
    Actually i will melt the PLA in an oven first, so I should be left with copper only.

    Let's see, it's experimental.
    Regards from Switzerland
    My 2.5 Upgrade Thread

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    Senior Member Athlon's Avatar
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    if you melt the pla you wi just get copper dust

  5. #5
    Senior Member Hugues's Avatar
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    Quote Originally Posted by Athlon View Post
    if you melt the pla you wi just get copper dust
    not according to this update:
    https://www.kickstarter.com/projects.../posts/1159419

    50534112f3321f6edefc525cacae1c4a_original.jpg

    But i will try and let you know.
    Last edited by Hugues; 26 October 2015 at 1146.
    Regards from Switzerland
    My 2.5 Upgrade Thread

  6. #6
    Senior Member Hugues's Avatar
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    Quote Originally Posted by Hugues View Post
    ...
    Here's what i'm planning to do this winter:

    - Design and 3D print a new headlight. Never quite liked the one i have. Maybe something like this could be cool.

    - Design and 3D print new side covers. I would like to replace the 2 disks i have on each side of the bike and make up some kind of air intake or outake, inspired by this cool car here

    - Reprint my dashboard with my SLS printer

    - Move up my foot pegs, they're too low, my boots are getting worn out, LOL. The place where they bolt on the frame cannot be changed, so i have to design an external bracket, i'll try to print it with my SLS printer out of polyamide-carbon. It's very stiff and has a nice slight flex.

    - Design and print a bracket for my new contactor

    - Design and print some "skins" on my front fork and swingarm, printed in black, and i will cover the bike first with a burnt orange vinyl film. Let's see where i go with this.

    - I have yet to receive the copper filled PLA i bought on kickstarter. When i get it, i need to design and print a heatsink for my motor.

    - Might try to add some fins on each side of the front body panels.

    - Designing and 3d printing some kind of spoiler on my rear fender.

    - Check all battery connections and wiring

    - Repaint body work and rear fender, a bit darker but not completely black.

    That's gonna be another busy winter, cool, i like this.

    I'll update this thread when i have something to show.
    Did not put a lot of updates but some work has been done:

    - new headlight: i designed it but 3d printing would have been tedious. So i bought this one instead

    - New side covers: designed them, but again, too complicated to print. So i asked the guy who designed my fairings to make them out of fiberglass. Pictured below, still need to add carbon fiber fins and paint them.

    - 3d printed my dashboard

    - we've thicken the rear fender, pictures to follow

    - complete paint job, frame and all fairings, black matte, good job. I show the "gas tank" below

    Pictures of the final beast when assembled, soon i hope.



    side covers.jpggas tank.jpg
    Last edited by Hugues; 30 May 2016 at 2040.
    Regards from Switzerland
    My 2.5 Upgrade Thread

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    Was your motor overheating? When you end up getting that special filament and design your AC-20 heatsink, I might pay you to to make me one.

    (Your ride looks amazing)

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    Senior Member Hugues's Avatar
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    Quote Originally Posted by Jayls4 View Post
    Was your motor overheating? ...
    Sometimes yes. For example when riding back home up hill after a rough ride, if I continue to accelerate at full throttle, the motor will derate. Controller is fine. Motor is already ventilated with forced air in the intake.
    Regards from Switzerland
    My 2.5 Upgrade Thread

  9. #9
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    Quote Originally Posted by Hugues View Post
    Sometimes yes. For example when riding back home up hill after a rough ride, if I continue to accelerate at full throttle, the motor will derate. Controller is fine. Motor is already ventilated with forced air in the intake.
    haha... well crap.

    My Sandrail is around 1000 lb. I do have the advantage of 4-speeds to work with to reduce the load, but I need to think of something to improve motor cooling. I think I remember your big bike was about half the weight of my vehicle, so it's almost guaranteed to derate on mine.

  10. #10
    Senior Member Hugues's Avatar
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    Quote Originally Posted by Jayls4 View Post
    haha... well crap.

    My Sandrail is around 1000 lb. I do have the advantage of 4-speeds to work with to reduce the load, but I need to think of something to improve motor cooling. I think I remember your big bike was about half the weight of my vehicle, so it's almost guaranteed to derate on mine.
    mine's about 620 lbs without driver.
    Regards from Switzerland
    My 2.5 Upgrade Thread

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