Build Your Own Electric Vehicle You need this book if you want to build your own EV

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pcarlson1979's picture

ERider 5000w

Well I heard yesterday that my 5000w scooter has been picked up at Melbourne and should be delivered to my home in Canberra this Friday may 6th!

Cafe Racer/Tracker build in New Zealand

After years of looking at motorbikes, riding some, dreaming about owning or buiding one, I have finally settled on building a cafe racer/tracker style electric motorcycle. I've just bought a 1986 Honda CBX250 rolling frame and am currently investigating all electric components.

I've looked into Lithium Ion batteries from a company called LifeBatt but the costs are high. The batteries are roughly $2000 NZ (US$1400) each and apparently also require a battery protection module (NZ$1000). They've also quoted NZ$2000 for a compatible charger. For my total budget of $5000 this is waay to expensive, so I think I'll have to go for deep cycle lead acid batteries. I'll keep investigating Lithium Ion possibilities but at the moment Lead is winning.

I've found a good site at EVAmerica for pretty much all the components required and even though frieght will cost almost NZ$1000 after tax it's still the best option.

Any help or suggestions are welcomed.

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Electric Recumbent's picture

Need help with brushless wiring

I'm new to this site. I was wondering is someone could help me with the wiring on my project. I have a mars brushless motor and a kelly KBL48301 controller. (I purchased the motor from briggs and stratton outlet and they said it is an etek motor. After receiving the motor I believe it is a mars. I guess it is a direct replacement.) Anyway I'm having some trouble wiring the hall sensor and can't seem to find a wiring diagram. I am told there are 2 power wires and 3 hall sensor wires. Does anyone know which color wires from the motor should be connected to the controller. Thanks.

moveon70's picture

Upgrading my Electra Voy Bicycle

I bought a used ebike purely for the experience of upgrading it.

I stared with a Electra Voy bike/scooter which I found on Craigslist and boght for $150. It has a 36V lead acid battery set which feed a 180W hub motor.
My ultimate goal (and I have all ready ordered parts) is to upgrade it to a 48V, 1000W, LiFePo4 system with regen breaking.
I ordered the motor and controller (with regen breaking) from "Golden Motor" ($400), and the LiFePo4 battery with Battery Management System from a Chinese distributor through ebay($400).

It will take a couple months for my new parts to come in, so until then I thought I would mess around with the current system. The 3 12V, 12Ahr batteries were shot. I picked up some used 12V 7Ahr batteries from a surplus house for $5 each and decided to see if I can make them work.

This scotter has allowances for two sets of batteries. When one set dies, you can switch to the other set. I was interested in putting two sets (a total of 6 batteries) but do not want to switch between them. If the two sets are simply wired in parallel, then one weak battery brings down both sets. Instead I decided to use some diodes to seperate them out. After drawing the schematic I realized that it was actually the same diode lay out as a bridege rectifier. (see attached file for schematic).
I bought an NTE5340 40A bridge rectifier from Fry's for $7 and it all ready has push on blade connectors, so it was easy.

So far, it works great. I can charge all 6 batteries with the 36V charger, and as I ride, the controller pulls the most current from the set with the most voltage. They basically drain together. Fantastic!

Next posting will be once I get some of my new parts in.
-Mark

solutionsgem's picture

Solar Powered Portable Generator to Recharge my Electric Bike.

We have always wanted to become energy independent. We ware finally able to do it a few years ago when we got our 3 kilowatt photo voltaic system. By then we thought we only needed our electric vehicle to become independent from the oil companies. We got ourselves a XB-700Li Lithium power scooter on August 2008. We advertise the scooter as a Solar Powered in our area. People ask us how we power the scooter with the sun. For people familiar with Photovoltaic systems ask me where the solar panels are. We did think about installing solar panels on the bike but we quickly realized that was not a good idea because of weight and sun damage.
It is a great way to start a conversation. We explain that we have a Photovoltaic System at home. Then they ask me how much is the system. We have to be honest with them. It is an expensive purchase up front. But with all the incentives and tax breaks my system should paid itself off in seven years.
That to must people is too long and risky.
That got us thinking into building an affordable portable photovoltaic generator to recharge our bike. We liked the idea because it serves a dual purpose, it recharges our bike and it is a back up/emergency battery for all our computers. We wanted to stay under 300 USD.
We started with two SunPro automotive 15 watt Solar panels, one Exide Orbital Deep Cycle Non Spillable Battery. We liked the Solar panels because they include a Charger Regulator with each panel. The regulator helps protect our battery from overcharging. We then used our 300 watt DC to AC Inverter we already own. We have no idea how much energy the battery is capable of storing. The most we have drained it from the battery is approximately 400 watt/hour. We had to stop draining the battery because of the low voltage alarm went off in the Inverter. We measured the watt/hour with our Kill a Watt meter. We know the 400 watt/hour number not accurate because there is much current lost in the conversion from 12 DC volts to 120 AC and back to 48 DC Volts. We know there must be a more efficient way. That would involve a direct conversion from 12 to regulated 48 volts.
Does anyone know how much energy those orbital Lead acid batteries hold?

Here is the battery:

IMAG0188.jpg

He is a closer look at its specifications:

IMAG0187.jpg

We got the orbital battery because we were told they were easier to store and that it would not spill any acid.

Here are some of the connections, the DC to AC converter and the battery charger regulator that came with the solar panels.

GENERATOR

Here are our two 15 watt rated Solar Panels on our roof facing South

IMAG0141.jpg

We do not ride our bike on long trips. We have only put about 1000 miles in eleven months of owning it. The generator is almost enough for our riding needs. We sometimes use the regular AC outlet to finish charging the Scooter after longer rides.

We will eventually install a second battery and perhaps more solar panels. These solar panels are not very efficient but for the cost they are fine.

We recently found these same SunPro panels on sale at Costco for $250. The package included four 15 watt panels for a total of 60 watts, mounting hardware, battery charger regulator and a DC-AC converter. We though that was a very good deal. You can find a similar deal at eBay.

Harbor freight sells a similar package that produces 45 watts. Here is the link:

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=90599

Our set up is not perfect and not much electricity is stored but it helps become oil independent on a budget.

Let us know what you think.

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