Kawasaki zxr-E

[flo]

Hi,
no. I guess i phrased that misleading.

Of course i will glue the parts.
Its just the fit of parts that makes it possible to actually just klick it together and it won`t come appart. guess you could load it with 5kg easy before it would come undone.

Flo

[flo]

Happy new year everyone.
Being such a nice warm day i decided to do a reality check before committing to glue up the bat box.
the leafs fit in, actually i left a bit too much space lengthwise.
will put a tiny bracket of some leftover fiber-sheet across the with to take up the space.
fiddled for every mm just to have some wasted .. but i am not going to do it all over again..
Forgot to take pics.

Getting a bit weary i then checked the fit in the bike.

20210101_150223.jpg20210101_150158.jpg20210101_150146.jpg

Perfect no need redoing.

Glue drys atm, bus-bars up next.

Flo

edit: once more the server decided to rotate one pic ...

[flo]

HI
Progress has slowed down some, there is just some tasks to finish of before cable-work to be started.
Anyway, 5 cells in the box, all torqed up and rock solid.
20210103_160513.jpg
Glued in some brass sleeves in order to transfere the load better into the holder.
20210103_160520.jpg
Also i had to first finish the attachment pieces for the 6th cell (laying flat on top). which also makes sure there is absolutely no play within the cell-block.
20210104_092010.jpg
Got some bus bar wooden mock-ups milled to check fit and started to mill them from 3mm copper...
just to realise that i need to order some cable eyelets(?) as the center tab is m4 and i have designed all for m3 for the simple reason that i still had some from m previous build.

No biggie just some delay...
Stay tuned

Flo

[flo]

Hi

color coded sens wires and plugs
20210105_131313.jpg

carefully attache busbars and sens wires
20210105_181812.jpg

Taped up awaiting the last cell on top..
posponed this to stay focused as this will be the most tricky bit
starts getting bl.. y heavy
20210106_103739.jpg

Hope i can get myself to tackle this tomorrow

Flo

[flo]

Hi
had a dab at the most tricky bit , only took three trials
might not look as bad..
20210108_161629.jpg20210109_153016.jpg

but it has to fit in there perfectly:
v3 027.jpgv3 025.jpg

also added two tiny holders for support, so in the worst case of breaking, the horizontal part cannot touch the underlying bus-bar.
20210109_153211.jpg

As the glue for those holders needs thorough curing i took advantage of the fine weather to cut the tank.

Tank had been washed 6 times before and aired for a couple of days. Better safe than sorry i did a final test sticking in a burning candle, attached to a long rod. A trick i had learned from my neighbor.
No surprises i then basically dug the tank into the snow to keep the heat of the paint.
Works brilliant
20210109_144909.jpg
Still need cleaning up but i have to get a different disk for the tool first..

Stay tuned

[Stevo]

You are making fast progress. Maybe you will have it on the road before the snow melts LOL

[flo]

Hi Stevo,

yup that´s the plan
Well actually the plan had been to fabricate all Parts and modules during christmas hollidays. Ready to be installed late winter early spring - we want to ride as much as possible don`t we?
Plan fell through as i got stalled again
I have crimping connectors here 35mm2 for m6 but the things fall of the cable after crimping them... rechecked with an 35mm2 M8 and it stays on rock solid.
Anyway found some that will hopefully fit, should be here by tomorrow.

As work started again progress will slow down naturally.
Nothing to worry - got 90% done within my planning. And winter just started..
Hope to have the batterie module done next by next weekend.
So stay tuned

Flo

[flo]

Hi,
after the new crimp connectors arrived finally saturday evening (so much for ships overnight) i was set to tackle the last cell.
first of, a last mock-up topplate was milled from scrap to check the sit of the e-stop in relation to that last cell.
20210117_111631.jpg

No more excuses.

This is where all has to go on to:
20210117_092750.jpg

Place the last cell on top but set slightly back from bus bar to avoid shorts during the next step:
20210117_093804 (2).jpg

attache sens wires and don`t get confused, as there is now no visual with the underlying cell:
20210118_184353 (2).jpg

slide cell forwards and connect with the rest of the pack, put on fiberglass protectors, which mainly serve to prevent shorting when getting the pack into the bike-frame.
As can be seen the left one was milled to the wrong sice
20210118_184721.jpg
cannot be bothered tonight, gonna cut it tomorrow, will connect up the e-stop then too.

Stay tuned

[flo]

..I have completed the battery box.
Like this the whole assembly can be put into the bike without any wires "life".
20210123_113105 (2).jpg
20210123_164904 (2).jpg
20210123_164918 (2).jpg
The two red lines with fuse holders will connect to charger and dc/dc.

Also had a first go at the wiring scheme.
Some of you will find this familiar .. it s actually just a revised version of my sachs`s scheme.
The principle should be the same, only the connectors might need some redo.
Anyone care to have a look at it?

Stromlaufpan v01.jpg

stay tuned

Flo

[flo]

Hi all,
very slow progress lately.
After finally receiving my axle and spur gear, beautifully crafted by my buddy Michael, i thought i could pic up some speed again.
But stupid me, i told him the wrong with to turn down the sprocked. So it still does not fit.
So very little could be done in the time till he manages to shave some time at work for another attempt.

20210206_172448 (2).jpg20210206_172741 (2).jpg

In the meantime i got the ball races planted into the holders, secured by some locktite. Snug fit as expected.
20210207_145057 (2).jpg

Also changed my mind about the two fused lines , i wrote about in my last post. For the dc/dc it might have worked but not so for my charger.
Instead i got hold on some anderson (mini) powerpole connectors. As these are fully housed this enabes me to work on the bike same as two fused cables.
Those connectors are really small and availible from 15 to 90 amps at 600V isolation.
Well worth a look .
20210207_152230.jpg20210207_152350.jpg

Still trying to find a supplier for a domino hall throttle, preferable in EU. Already contacted the mfg but no answer from them about dealers around.
Anyone having a source for them?
Let me know.

Stay tuned

Flo