Custom 1000watt'48volt 'Rat' e-Trike

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AussieJester
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Custom 1000watt'48volt 'Rat' e-Trike

G'day all

For the last ~6 months or so i have been building electric trikes,
In all i have fabricated 4 frames of which 2 have made it to completion
the other two scrapped in favor of the "upgraded/improved version'
This "worklog" below is a condensed version of the 40 page worklog
this condensed version containing ONLY the latest
build

Today i just finished re-assembly after the prep/paint process sooo...

The idea behind this project aside from the "fun factor"and getting me away from the PC modding scene which for the last 8 or so years has taken up ALOT of my time and $$$..was to fabricate something 'environmentally friendly' that would be useful for getting my ass to the local shops and pub. The reason for a trike is due to me being a paraplegic, thus a 'standard' two wheel bicycle wasn't an option...By law this trike ISN'T legal for on road use (i will be using it anywayz, mainly on bike path which is also illegal but meh...) W.A electric assisted bicycle laws state that maximum motor size is 200watt and the bicycle must have operative pedals...mine complies to neither BUT i do have a 200watt sticker Photochopped up for the motor hehehe the pedals, well...lets hope the Police let that slide seeing i can't use pedals anywayz...

I decided after much research and alot of help from a handful of members on particular forum (i can't recommend it, it is very poorly run ...which is a bit unfortunate there are some great fellas there...but, i digress...)...I decided to to go with a 'non hub motor'setup, this would entail a 1000watt 4 brushed electric motor running a jackshaft arrangement driving a rear wheel through the trikes derailleur/gears.

The motor and sprockets were sourced from a U.S company TNC Scooters while the speed controller (3rd one blew the first two were cheapies from TNC) came from Kelly Speed Controllers Brakes, front and rear hubs and the rear 'trike conversion' along with disk brakes where purchased from ChoppersUS Everything else used 'bicycle wise' (aside from tires) were sourced from the side of the road during Curbside collection, the tubing used was purchased from Impressive Steel...cost around 60 bucks to build the frame and springer forks, i bought a Pipe bender off EBay to bend the tubing along with a gas lees mig welder to weld it up...

Here's a few pics of the stages of the project...

//members.ii.net/~aussiejester/index/pictures/Custom_crusier.jpg)

Once i had the trike to this stage (in above pic) I rode it around for a
month or so making small adjustments as needed. The trike at
that stage had a top speed of 79km in second gear, Unfortunately
at that stage i didnt have a gear leaver to change gears, that has since been rectified hehe.. (Realistic top speed is in excess of 100km/hr, I'm not really interested in traveling much over 40km/hr though due to the fact bicycle tyres/rims simply aren't designed for this purpose, i want FAST acceleration) with the trikes 'bugs' ironed out and gearing sorted i proceeded to strip the bike for prepping and painting, few pics of that process below-->

At this point the majority of the painting was complete, the frame was sanded with
400 grit then hit with 2 coats of etch primer followed by a coat of primer filler
then 4 coats of Matt Black paint...

With the frame complete the springer forks were prepped in the same
manner and also hit with Matt black paint...

With the both frame AND forks painted installing the stainless steel braided brake housing was the next course of action followed by installing disk brakes calipers-->

With the anchors ready for action a battery box was knocked up to hold the 4 12volt 18ah slas batteries...I decided i would use plywood and aluminium angle for the battery box. I had orginally wanted to use a newer battery technology, when i started this project the Aussie Dollar hadnt taken a nose dive yet and 48v 20ah Lifep04 batteries
were well under 700 dollars, NOW they are up over a grand, a lil too rich for my blood at this time, when i do get the newer battery tech though it will push the trikes range out to double what it is now, currently 20km at around 30km/hr would be achievable, faster you go the less distance you go...

Once the basic box had been cut out, i used 88 self taping screws to attach aluminum angle to the corners to hold the box together, once done it was painted up came up alot like this-->

OH LOOK!!!11oneone its ME :-P

As mentioned earlier i finished wiring up the trikes electrics this arvo, the final shots
for now (i still have a rear tray to build and fit, need somewhere to put the cartooon of beer :-) )

I only need to fit the chain and adjust the Deore Rapid Fire Shifter and i can takez him for a blat :-)

For now that's it, it has been a fun project and given me a glimpse into the performance of electrics albeit on a 'bicycle' scale. With the ever increasing rise in OIL we are surely to see more hybrid and electric cars on our roads, unfortunately whats holding back the advancement is the battery technology, it is there but frightfully expensive...Anywayz, hope this has been of interest to those that took the time to have a geeko, if you would like to see the full 40 page worklog containing ALL work done from the start including the other 3 frames head on over to either

OZ Case Mods

Alternatively motoredbikes.com

I have also got a few videos of the trike in action the latest can be viewed on Youtube

best veiwd in HD mode

Happy to answer any questions...OH, im sure someone will ask "how much does it cost" well, good question the short answer is "I don't know" i didn't keep track, suffice to say well under 1000 dollars to the stage seen in pics, prolly in the 800 dollar range (factor in my time THOUSANDS LoL)

Thanks for lookin

KiM

aka AussieJester

dogman
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Re: Custom 1000watt'48volt 'Rat' e-Trike

First class AJ. Nice to see it all together, and not so many pages to wade through. I just gotta get a wire feed, and learn to weld. What I want is not for sale, and if it was, I couldn't afford it anyway.

Be the pack leader.
36 volt sla schwinn beach cruiser
36 volt lifepo4 mongoose mtb
24 volt sla + nicad EV Global

Old_Scoot
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Love it! Great job.

RANDEL24
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Awsome Trike AJ. Great job! I'll checking in on your progress,Randel Hanford Ca.

AussieJester
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Heeey Dogman :-) Cheers mate...I had been meaning to pop it up here been a member for awhile totally forgot about
the site to recently, wasn't sure what section to put it in even LoL i stuck it in another section first by mistake hehee.... cheers
anywayz mate...can also follow my builds on Motorerdbikes.com in the powered trike section if your interested in seeing future work :-)

oldskoot & RANDEL24 ...thankyou fellas appreciate the interest :-)

KiM

essconm_lee
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Very nice !

Essconm

AussieJester
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Thanks Lee :-)

Update

Well, the last few days i have been out in the workshop
constructing a rear tray for the trike...I have been taking
it slowly doing small amounts each time i head out, i have
now got to a point i think is worth an "update" to
my worklog :-)

I have used the remaining plywood left over from
constructing the battery box, the plywood came from an
old Wardrobe we picked up from curbside collection and
smashed apart for the plywood sometime back FINALLY
found a use for it WOOT hehee...anywayz, heres a few
happy snaps of the construction process thus far fellas-->

//members.ii.net/~aussiejester/index/pictures/Custom_Cruiser_tray_series_pic_1.jpg)

The tray has been sanded and undercoated and hit with a
coat of primer filler, require a light sand and then will be hit
with Matt Black...I have aluminum angle cut and scotch
brighted for the edges (as per the battery box was
constructed
) the holes around the upper edges are too
hook a few small Ocky straps on, there will be aluminum
edging to go on around this top edge also to strengthen it...

The metal structure the tray will bolt too will also have
the 'tow hitch' attached to it that the wheelchair will
hookz too, i will be using a LARGE steel carabina for
the 'hitch'

I hope to have the tray painted and mounted tomorrow
along with the tow hitch complete.

Shall be back with completed tray pics soon :-)

KiM

Old_Scoot
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Man, I love the steampunkish look of this trike.

spinningmagnets
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Brilliant work, AJ! absolute magic.

Stay on the bike trails after you've had a sip o' the amber nectar at the pub, mate!

AussieJester
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Cheers fellas, lil more progress to report-->

Update

A very productive day UNFORTUNATELY not quite as productive
as i had hoped. Never the less IM EXTREMELY happy with the days progress...

I managed to finish fabrication of the tray mount
and tow hitch for the wheelchair BUT wasn't able to complete
the painting, of the tray or mounting structure..

shall finish this over the weekend

Some pictures of the days work-->

//members.ii.net/~aussiejester/index/pictures/Custom_tray_tow+hitch+series+pic-1.jpg)

I couldn't be more happy with the result, 5pm this
afternoon i hooked up the wheelchair and did a lap around
the block with it in tow, i get FULL LOCK on the
steering of the trike and still have 2 inches clearance
between the front castor wheels on the wheelchair and trike
rear wheels...I can EASILY hook/un-hook the wheelchair
once seated on the trike, SWEET setup im so rapt how well it
has worked out, from the idea in my head to implementation it
has come together beauuutifully...:-) ...

NOW please keep in mind what is seen in pics is
a "work in progress" there are some "finishing touches"
to be added, (aside from the obvious prep-n-paint)

When riding the trike this arvo i didn't eve notice the
difference in acceleration or top speed with the wheelchair
in tow ...more tomorrow fellas..

KiM

p.s I Have no idea WHY but my wheelchair is powdercoated BLACK not the funky purple colour seen in pics very ODD..

AussieJester
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Rear Tray & Tow Hitch Assembly Update

[i]Update
[/i]
Well a little closer to completion unfortunately i ran out
of Matt Black paint this arvo :: sigh ::

I have completed prep work on both the tow hitch mount
AND the tray itself...The hitch mount has also been
fitted. All that i need do now is finish shaping and fitting the
aluminum 'trim' for the upper surround of the tray...
Thus far i have finished assembling the tray (aside from
all aforementioned trim, one side is complete and fitted)

-->

//members.ii.net/~aussiejester/index/pictures/Custom_tray_tow+hitch+series+pic-2.jpg)

(apology's for the 'darkish' pics was dark tonight when finished and the lighting in the workshop ain't to special when it comes to snappin' pics im afraid)

The tray has been assembled as per the battery box was
ie. glued and screwed...OH...i have also picked up a couple
of meters of 10mmx2mm aluminum which i will be cutting
to lay (screw) to the 'bed' of the tray at around 50-60mm
intervals, this will protect the woodwork/paint should look
pretty neat too against the Matt Black finish...I have also picked
up tubing to slide over the 'U' bracket on my wheelchair too
eliminate the 'metal 0n metal' affair when
the chair is clipped on the carabina :: wink ::

OK..i think i'll have this thing whipped tomorrow, AND ill get to take
a trip to AutoOne to get me another tin of Matt Black
paint WOOTz hehehe...

More tomorrow chaps...

KiM

AussieJester
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Points: 15
FINALLY!!!! After 349 days and 4 frames later i'm FINISHED!!

FINAL UPDATE

AS the subject (title) suggests the trike is now
FULLY finished..haha... well...is ANY DIY project
EVER 'truuuly' finished? hehehe there are a
few 'minor' things i will be 'tinkering' with in
the future...mainly motor wise(re-wind & watercooling,
suffice to say-->

//members.ii.net/~aussiejester/index/pictures/Custom_e-trike_completed_series_pics1_800.jpg)

For now though this will be the final installment, appreciate
all the feedback/advice i have received throughout this
project, i do sincerely hope it inspires some to have a crack
at their own e-bike projects, either way I hope those that
have taken the time to read this worklog have enjoyed the
experience and taken something from it :-)...best wishes
& Happy Easter to all...until the next build its "asta la vista" :-)

KiM

aka 'The Apprentice Gangsta'

AussieJester
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New Video Overview of Custom Trike Build

I have been meaning to do a video overview of the trike since finishing it but
have been distracted by one thing or another each time i venture into my
workshop SO this morning i decided i would set aside some time
to do a video. Apologies for the shocking quality i/m still using my
Cannon Powershot A630 digital camera to take the video.
This is probably nothing new to most as all the stills are on the forum,
the video was more for those on YouTube i guess, these are the ones
that haven't really had the opportunity to view the trike up close and see
what its made of.SO without further ado i present to you from The Garage
staring a sexy hunk-a-man "AussieJester" along with a highly
trained production crew "me" hehehe-->

KiM

AussieJester
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Re: Custom 1000watt'48volt 'Rat' e-Trike

I'm not usre if i ever mentioned it in the worklog but from
day dot i wasn't entirely happy with the shape of the seat
on the trike, the front had a 'squareness' to it that didn't
suit the shape of the frame it sat on, so over a few stubbies of Jack
Daniels black last night while the lads were over i ripped the seat
off re-shaped it more to my liking then re-fixed the original
seat cover on-->

//members.ii.net/~aussiejester/index/pictures/remodeled_seat.jpg)

How it was accomplished was via a electric carving knife
to 're-shape' the foam. I have re-upholstered MANY
motorcycle seats over the years, part of my the company
my father owned for more than 20 years involved
motorcycle seat upholstery which i started doing in school
holidays to earn money for my hobbies at the time haha...
here's a pic i took this morning out in the sun-->

//members.ii.net/~aussiejester/index/pictures/Custom_Trike_Cruiser_Latest_Pic_new_seat_design.JPG)

The 4 buttons still need to be pulled down they are just
'stuck' temporarily with a dob of glue to hold them in
place for picture purposes ATM...I like the way the seat
now 'sits' on the bike, it fits the whole shape of the backbone
of the frame alot better i think, also i rounded the edges more
so the seat is slightly thinner now as a result leg positioning
is more comfortable and doesn't tend to push your feet outward
and off the pegs, not a problem if you have leg strength but
i dont :-)

KiM

Badger
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Awesome job what is thw jackshaft?
Also why didn't youy go with a hub motor? Just curios as I am new to this sport.

AussieJester
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New 20in x 4.25 rimz and tires

Im not a fan of hub motors they are heavy and require alot of volts to get any sort of performance out of them compared to a non hub motor running through bikes gears...

Received a delivery from Alan @ ChoppersUS this morning my new 20in x 4.25 rimz and tires...couple of pics for ya all-->

//members.ii.net/~aussiejester/index/pictures/20X4.25%20pic%201.JPG)

//members.ii.net/~aussiejester/index/pictures/20X4.25%20pic%202.JPG)

//members.ii.net/~aussiejester/index/pictures/20X4.25%20pic3.JPG)

Shall workout the spoke size required order them and lace these puppies up :-)

Back with more pics when they are fitted...

KiM

AussieJester
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Motor Rewind

I have also rewound my Unite 1000watt motor with AWG20 size magnetic wire (stock thinner AWG23 is used in a single wind config) in a double wind config herea few pics

Here's a few before and after pics of my rewound Unite 1000watt motor with AWG20

Few before shots

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic1.JPG)

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic2.JPG)

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic3.JPG)

Stripped and ready for some paint

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic7.JPG)

End plates stock on left enlarged vent holes on right

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic8.JPG)

Both End caps with enlarged vent holes and additional holes added

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic112.JPG)

Read to rewind

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic113.JPG)

THE START!

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic114.JPG)

Progress shots of rewind including "secret weapon"

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic119.JPG)

Full 20AWG 11 x 2 == 22 Rewind pic FRONT

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic123.JPG)


Full 20AWG 11 x 2 == 22 Rewind pic FRONT

//members.ii.net/~aussiejester/index/pictures/tn_motor_rewind_pic122.JPG)

Waiting on shellac to be delivered to seal the motor before re-assembly.

KiM

AussieJester
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Re: Custom 1000watt'48volt 'Rat' e-Trike

..I finished truing these 'pimpin' 20 x 4.25in wheelz last night when the lads had left, wheeled the trike outside this morning for 'obligatory' pics. Note rear rotor and calipers still need attaching OH aha minor detail to the motor is still AWOL.-->

//members.ii.net/~aussiejester/index/pictures/Custom_trike_first_pics_new_rears2.JPG)

//members.ii.net/~aussiejester/index/pictures/Custom_trike_first_pics_new_rears3.JPG)

//members.ii.net/~aussiejester/index/pictures/Custom_trike_first_pics_new_rears_1.JPG)

Gives it a better...erm...'stance' i guess you could say hehehe..
I can see as things progress i will have less and less chance of convincing the Policeman SIR that this is a electric pedal assist bicycle with a 200watt motor :-|

Hoping the shellac or second motor will be in my hands within days...

More laters

KiM

Mick46
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Re: Custom 1000watt'48volt 'Rat' e-Trike

Which Maxxis front tire are you running??

paolojazzo
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Re: Custom 1000watt'48volt 'Rat' e-Trike

GREAT BYKE... I M BUILDING A TRIKE AND A OLDTIMER ELECTRIC BYKE  MY PROBLEM IS THE BATTERY..WHERE TO FIND CHEAP  LITIUM BATTERY ?   I USE TO HAVE A FRIEND HE COULD BUILD A 48VOLT 40 AMP BATTERY (6KG) FOR 300 USD.... BUT NOW HE STOPT... DO YOU KNOW ANYONE ? THANKS  PAOLO  paolojazzo [at] gmail.com

paolojazzo
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Re: Motor Rewind

beautiful..but why did you rewired the motor ? somenthing wrong or just much better power ? i have the same motor..should i do the same ? thanks paolo

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