I figure its about time that I start putting my project out there. I was recently featured on Autobloggreen, and I guess I didn't think that many people were interested. Then I found this place, and ecomodder, as well as a few other sites... so there's interest.
My website is: http://www.evfr.net and there are plenty of pictures, and a blog or two a week since I started last year.
About the project:
The bike is a 1986 Honda VFR700F that I found in Florida for $400 with no title, in like new condition. Brand new tires, been stored for 10 years with $4270 miles on it. I got it shipped to Oregon for $675, and parted out the engine, exhaust and electrical and just about broke even. The bike was essentially free. The title was lost, but it checked out, so I found another frame for $150 and swapped it after engine removal.
I'm currently working with a company in Portland on building a very robust 600A 156V fully programmable series motor controller. Its in test right now, and we're finalizing the design. We've got a PDA communicating with it for my display. It will display MPH (tach input to controller), motor rpm, battery side voltage and current, motor side current and voltage. It will display each battery voltage in the future. We're also working on battery balancing and charging designs.
A couple months ago I found an Advanced DC K99-4007 motor on a surplus website, and bought 2 of them. They are equivalent to the ADC K91-4003. They max out at around 50 or so ftlbs or torque and 18hp. Its 56lbs and has plenty of thermal mass. max RPM is around 5500. Just need to machine the shaft for a keyway and shorten the shaft.
I also scored 12 18Ah batteries (will do series parallel to get 72V) from another EV Motorcycle guy. They're about 13lbs a piece, for about a 36Ah pack at 72V, and 54Ah at 48V. Still working on how I want to charge and balance them.
For now, I'm using a 48V GE Controller I got from some guys that I used to work with at GE in their GE Power division (I used to work on the control systems for wind power). They happened to be using something similar for blade pitch testing. They needed something DC in case of power loss so they could feather the blades. This was one of the extras, and was donated. They also threw in an Allbright SW190 contactor.
Just picked up a Vicor 200W 48V to 12V DC DC converter for my accessories/lights/contactor for $20... score.
So I've got batteries, DC-DC, motor, controller, contactor, rolling chassis. I need to fabricate the motor mount (the Portland guys are helping me), make a battery cage and some battery/motor cables. I'm trying to pick sprockets and think I'll go with a 4:1 ratio. Some guys with eteks/perm132 go 5:1 up to 7:1. Other guys with smaller ADC motors go anywhere from 3.5:1 to 4.5:1. My motor is larger with more power, so 4:1 should be just right. I'm changing from 530 chain (#50) to #40 chain to make it more quiet. Sprocketspecialists have sprockets for me for under $100, and surpluscenter.com has sprockets and nickel chain. I need to start looking for a charger for short term, we're working on distributed charging right now, and its being tested.
So thats about where I am. Comments, critiques appreciated.
p.s. don't tell the VFR guys that I dismantled the VFR before I finish :)