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