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Thread: 1984 Kawasaki GPz900R Build

              
   
   
  1. #21
    Member Luma's Avatar
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    So how many you packing in there on your 3D mockup? Difficult to count :-)

  2. #22
    Electric Warrior CaptainKlapton's Avatar
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    Woops, should have put that in. It is a mockup of 84cells (28s3p) in in two groups both divisible by 3 to make paralleling easy (30cells in the top group and 54 in the lower). That would give about 106v nominal and roughly 98Ah. So it is definitely a rework of the original modules but not so far off that it would be a mess to use the original terminals, I hope.
    The comparisons for weight and capacity I did were against 140 16Ah Enerdels in a 28s5p configuration.
    Last edited by CaptainKlapton; 20 January 2014 at 1113.
    "Never let schooling interfere with your education."
    -Mark Twain

  3. #23
    Electric Warrior CaptainKlapton's Avatar
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    Did some rough CAD of the heat sink for the AC-20. The idea is that I could just buy an aluminum pipe with a 6.5" I.D and a 7.5" O.D, put it in a lathe to cut the fins, cut it in half, drill and tap the holes and clamp it on. The fins are 3/8" high, leaving a 1/8" base for rigidity, and 1/10" wide. The gaps between fins are also 1/10" wide. This setup should be simple to machine and will give a ~324% increase in surface area over stock.
    AC20_1.jpgAC20_2.jpgAC20_3.jpgAC20_4.jpgAC20_5.jpg
    Last edited by CaptainKlapton; 13 May 2014 at 1941.
    "Never let schooling interfere with your education."
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  4. #24
    Electric Warrior CaptainKlapton's Avatar
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    A little teaser of one of the many sub projects that make a build.
    photo 1.jpg photo 3.jpg photo 2.jpg

    As a side note I think I have finally decided on a battery configuration. It looks like 30s3p LEAF cells is going to be as good as it gets for my college student budget.
    Last edited by CaptainKlapton; 10 August 2014 at 0712.
    "Never let schooling interfere with your education."
    -Mark Twain

  5. #25
    Electric Warrior CaptainKlapton's Avatar
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    Massive Update

    Now that I am finally done with school, graduating tomorrow actually, I can get back to this build.
    I have mostly been doing little things after I get home when I wasn't too tired, but it added up.

    Here is what I believe to be the final layout of the power train:
    Full-Layout1.jpg Full-Layout2.jpg Full-Layout3.jpg

    That is a 30s3p LEAF pack, the AC-20, with its heat sink, and the frame struts (not the final design for these but the same general shape)

    I have also continued working on the tank:
    photo 1.jpg photo 3.jpg

    Now the trick is to make it look respectable... I am going to trim the corners of the heat sink to make it flow better and be less dangerous. The Curtis fits inside the tank tightly so the tank will need some more persuasion.
    "Never let schooling interfere with your education."
    -Mark Twain

  6. #26
    Electric Warrior CaptainKlapton's Avatar
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    Simulation

    I have also added a great deal of functionality to my simulation program I wrote in Octave.
    Using it I evaluated six battery configurations and five different gear ratios. The following is what I came up with for the best performing combination:

    Battery Configuration: 30s3p

    Nominal Battery Voltage: 112.5v

    Battery Capacity (C/3): 9.674kwh

    Total Mass w/ Rider: 283.6kg

    Final Drive: 420 Chain 15:87 ratio

    Top speed: 105mph

    0-60mph: 3.34 seconds
    0-80mph: 5.96 seconds
    0-105mph (prone): 25 seconds

    Peak Power: 58 (RWHP)

    Range at:
    City (19mph): 115.3mi
    55mph: 80.0mi
    80mph: 50.0mi
    Average: 81.8mi

    I have a fairly in depth report for the program I wrote to get these results, if anyone is interested PM me.
    "Never let schooling interfere with your education."
    -Mark Twain

  7. #27
    Electric Warrior CaptainKlapton's Avatar
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    Fork Swap

    After taking the forks apart and seeing what would be involved to make them more modern, I decided to just swap the front end of a more modern bike. That will give me a much wider range of performance goodies when I have the money as well as saving a good 15lb from using modern wheels and tires. Right now the front end off a ZRX1200R is looking like the best option. One of the main problems with a swap is that the stock fork is 800mm long, axle to top of tube, and all of the newer forks are considerably shorter, the ZXR for example is 766mm.

    To account for this and not mess up the steering geometry, I did a quick CAD mock up of some trees that will not only give me the stock ride height, but also a good deal of adjustment. I also like the idea of adjustable offset, so I added some eccentric bits around the steer tube which set screw in. They will give me the ability to adjust the offset from the stock 40mm down to 35mm.

    Yoke1.jpg Yoke2.jpg Yoke3.jpg Yoke4.jpg Yoke5.jpg
    "Never let schooling interfere with your education."
    -Mark Twain

  8. #28
    Senior Member Stevo's Avatar
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    Nice choice in chassis... I hope you're going to use the full fairing... Its nice and open, and wont hide all of the electronics like most of the modern bike fairings.

  9. #29
    Electric Warrior CaptainKlapton's Avatar
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    I am planning on using as many of the fairings as I can. It has always been one of my favorite bikes in terms of styling. But I don't mind showing a few of the electrics as well
    "Never let schooling interfere with your education."
    -Mark Twain

  10. #30
    Electric Warrior CaptainKlapton's Avatar
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    Just got a new front fork off of a Buell 1125R/CR that was parted out when Harley liquidated their inventory. Stock forks are 38mm O.D. while the new is 54mm. There is a 66mm length difference, but I can compensate for that. Both the new and old forks weigh ~4.6kg per leg, but I estimate that the overall mass will be around 5kg less with the Buell fork. With the single rim mounted disc, Buell was claiming a 7lb advantage over the R1 of the same era. Plus I can now run modern 17" wheels and tires. Now I just need to finalize the design of my custom triple clamps to make them fit.
    IMG_0045.jpg IMG_0046.jpg IMG_0048.jpg
    Last edited by CaptainKlapton; 17 March 2015 at 1825.
    "Never let schooling interfere with your education."
    -Mark Twain

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