Topic: Man, you guys are going to kill me.

[fmctm1sw]

I was lucky enough to find my motor second hand for a good price.

In my limited experience, that is the hardest thing.  Finding a massive DC motor...

[Alan F.]

Have you guys ever seen http://electricscooterparts.com/

Also just found:
http://www.electricmotion.org/
http://www.electricmotorsport.com/store/index.php
http://www.environmentfriendlystore.com/electric-motorcycle-parts.html
http://www.instructables.com/id/How-to-build-a-72Volt-electric-motorcycle/

This was a 76 CB550
http://www.treehugger.com/files/2008/04/voltzilla-diy-electric-motorcycle-forklift.php
There's a ton of easy to find stuff out there.
Alan

[unitedguitar]

I guess the part that really makes me wonder how it works is the "throttle." When it comes to an internal combustion engine it is a simple concept. Throttle cable operated by twist mechanism opens the slider in the carburetor allowing for more fuel and air to enter the engine causing bigger badder explosions. So how does the electronic throttle work? Is it like a really big potentiometer built into the twist mechanism?

[Alan F.]

http://electricscooterparts.com/throttles.html lists 3 types of throttles hall effect types, on/off types and 5KOHM potentiometer types.
I think it all depends on the type of motor controller you're using and what type of throttle input it requires.

[Sheik Yerbouti]

I guess the part that really makes me wonder how it works is the "throttle." When it comes to an internal combustion engine it is a simple concept. Throttle cable operated by twist mechanism opens the slider in the carburetor allowing for more fuel and air to enter the engine causing bigger badder explosions. So how does the electronic throttle work? Is it like a really big potentiometer built into the twist mechanism?

It's really simple. The controller has contacts on it for the throttle, which is just a big pot. There are also hall effect throttles, but the Magura Twist Grip is the standard throttle that almost everybody uses. Some controllers have the ability to digitally adjust your throttle response using your computer.

Check out

www.evalbum.com

You can search for just motorcycles or even sort by different types of motors and controllers. It gives you a good idea what the "real world" results of these conversions are like. And the process pictures also help.

[unitedguitar]

That is very cool. Only one problem they all have that I think you are planning on fixing. They are all so ugly. From the rendering you have I think yours will be functional and awesome in appearance. Maybe one day I will build an electric motorcycle. After I finish all of the gasoline powered ones that I want to build.

[Alan F.]

Has anyone seen these? http://www.zeromotorcycles.com/  about $ ten grand....

[Sheik Yerbouti]

I like the Brammo Enertia more.

[Alan F.]

Looks good.

[Sheik Yerbouti]

Okay guys. Got a lot of parts gathered.

Here's my motor. It's a D&D Separately Excited Motor. Meaning I get smooth regenerative breaking and very high efficiency. With a 500 amp controller it makes around 31 horsepower. It weighs 62 pounds and measures 6.5" in diameter by about 12 inches long.



My controller is a unit by PG Drives called Sigmadrive. It basically translates the input from my throttle and delivers power from the battery to the motor accordingly. They also control regenerative braking.



This is a contactor, which is like a big safety switch in case things go horribly wrong.



Two Magura twist grip throttles. One to control acceleration and one to control regenerative motor braking.



Sure Power DC/DC Converter. It basically takes my battery pack voltage (72V) and drops it down to a safe voltage for my headlights/signals/12v stuff to run on.

I also have a charger handy. I'm pretty much set aside from batteries, wire, some random switches and doodads. But those are the big components.

[Alan F.]

SWEET! Have you piled it all onto a scale yet to give a ballpark weight on the finished bike? Have you weighed your stripped down bike yet? Shouldn't be too tough to guess the weight of the batteries you intend on using...

It'd be fun to anticipate a weight to horsepower ratio so you can compare performance on similar weight/power bikes...

[Sheik Yerbouti]

The battery pack is going to weigh 77 pounds, the motor 62. The controller, DC converter, contactor together are less than 25 pounds. So we have a 165 or so pound drive system.

[Alan F.]

The battery pack is going to weigh 77 pounds, the motor 62. The controller, DC converter, contactor together are less than 25 pounds. So we have a 165 or so pound drive system.

So it'll weigh very much like a stock bike then eh?

[Zaipai]

subscribed!

.: Scott :.

[FunJimmy]

Finished concept sketch with flat planar access panels. This would be super easy for me to make.

Sheik

This sketch would make a great avatar.

Cheers
FJ

[Syscrush]

Cool, and good luck to you.  Given that you're using a CB, I think that your sketches look good.  I think that a 90's sportbike might be a better choice since the chassis is lighter, but I am excited about seeing how you make out with this project!

I've ridden a Zero-S, like the Enertia, but lately I'm daydreaming about the Empulse:

BTW - you might also find this interesting:

EV Drive moto conversion

[Gearheadgreg]

Larry has been playing with electricity latley, had some help from him when i installed my supercharger in VA,

[joeyputt]

This is an awesome project! I love that there is so much diversity on this site! SOHC4 truly is a classy place where there is so much support for one another by so many talented people!

Your renderings look great! I can not wait to see the finished machine and what better chassis to use than a vintage Honda!

[Syscrush]

BTW - what are you using to draw those renderings?

[Sheik Yerbouti]

Cool, and good luck to you.  Given that you're using a CB, I think that your sketches look good.  I think that a 90's sportbike might be a better choice since the chassis is lighter, but I am excited about seeing how you make out with this project!

I've ridden a Zero-S, like the Enertia, but lately I'm daydreaming about the Empulse:

BTW - you might also find this interesting:

EV Drive moto conversion

Thanks for the encouragement. I agree a sportbike frame would be better suited for this, but the nice thing about the CB750 frame is all the mounting points and the fact that it's got plenty of space. I'm hoping to keep the weight on this bike very low and manageable.

What did you think of riding an electric bike? I hear the sensation is quite interesting, hearing nothing but chain noise. Was the Zero S set up for regenerative braking?

The sketches were done in Autodesk Sketchbook pro on a Wacom. There is going to be a lot of tweaking now that I have all my components selected, and shoehorning all these into a frame is going to take some effort and serious thought.

[Syscrush]

The Zero S I rode was a restricted version just tooling around in a parking lot.

It was kinda cool but not what I was hoping for.  I don't think that they did their brand any favors by having people ride restricted bikes in a small space.

[Sheik Yerbouti]

The Zero S I rode was a restricted version just tooling around in a parking lot.

It was kinda cool but not what I was hoping for.  I don't think that they did their brand any favors by having people ride restricted bikes in a small space.

Yeah that's silly. The Zero tops out around 70 I think. But that doesn't change the fact that it's inexcusably ugly.

[Syscrush]

Is it OK if I ask where you're at in terms of budget?

I've got a CBR125R that I've always daydreamed about converting to electric - despite the fact that I have no need or really any use for an electric motorcycle.  I also daydream about putting a 450 motoX motor in it to use for trackdays - despite the fact that I don't really do many trackdays.

[Sheik Yerbouti]

I've actually been doing quite well because I got very lucky. I found a motor second hand for 400 bucks, and I snagged a controller, converter, and other bits from a company that was closing and selling off their parts. Right now I'm in at about 1000 bucks. Batteries are going to be another big expense, but I'll cross that bridge later. I figure I'll get a bit back when I'm refueling.

It pretty much depends on what you want to do. As soon as you want to go too fast and far it starts getting very pricey.

[Sheik Yerbouti]

Okay guys, I come to you seeking fabrication advice. In order to mount these batteries, I need to create some sort of tray or frame. The easiest and lightest way to go about this would be to use aluminum angle iron. But the problem is I have no way of welding it. I'm planning on using a combination of the existing motor mounts and 3 piece frame clamps to keep everything secure. I have a 3D model of the proposed battery placement at home. I'll post some screen captures of where they need to fit and what the batteries themselves look like and maybe you guys can help. My fabrication experience is limited, so every piece of advice helps.

Stay tuned for updates.