Custom Built Rat E-Trike

Post up a thread for your EV. Progress pics, description and assorted alliteration
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AussieJester
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Post by AussieJester » Fri, 11 Sep 2009, 21:11

(please be aware this worklog is upped on several forums as such some names mentioned in this worklog might not pertain to members in this particualr forum..apologies in advance for any confusion this may cause.)

G'day all

For the last ~18 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...

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...

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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 prep- ping
and painting, few pics of that process below-->

[img]hhttp://members.ii.net/~aussiejester/index/pictures/Frame%20Painted%20Series%20Pics%201.jpg[/img]

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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...

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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-->

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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 ge
t 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...

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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-->

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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 :-) )


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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

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

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 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-->

Image

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'

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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...:-) ...


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)

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 :

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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-->

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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-->

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

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.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.

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I have for the end of this post a video overview of my trike.
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-->

YouTube Video Overview of my trike



Happy to answer any questions...OH, im sure someone will ask "how much does it cost" well, good question t
he 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

tassie_tiger
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Post by tassie_tiger » Sun, 13 Sep 2009, 03:55

Thanks for sharing, you have a great flair for artistic and great lines on the frame, and the quality of your workmanship and end product is simply fantastic.
My hobby interests are EV's and competitions. aeva.asn.au for ev's and www.lottos.com.au for competitions. If your partner complains about you ev'ing, send 'em to lottos!

htial
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Post by htial » Mon, 14 Sep 2009, 00:27

That's awesome...   ...and looking at your quality of work I'd be surprised to see better...

Can I haz one???...   =^_^=

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AussieJester
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Post by AussieJester » Mon, 14 Sep 2009, 00:55

Cheers for the comments fellas...The trike is very andy i get to local shops on it, i live up in the hills here in Perth (Lesmurdie) so makes life alot easier for me rather than wheeling my wheelchair to do the shopping etc...AS i dont drive a car any longer.

Cheers again feelas :-)

KiM

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Post by BjBlaster » Tue, 15 Sep 2009, 22:25

Very nice job :) What annoys me is that we can't build these sort of "affordable" EVs and ride/drive them on the roads "legally". They are much more suitable for an EV than a ~1-2 tonne converted car!

Well done again on a awesome build! What sort of range do you get in Lesmurdie? That is some pretty hilly stuff...
If it's stuck, force it. If it breaks it needed replacing anyway - bj's shed

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Post by AussieJester » Tue, 15 Sep 2009, 22:40

Couldn't agrre more with you BjBlaster, what pisses me off even more is your allowed to fit a sub 50cc ICE motor and ride LEGALLY on the road WTF is with that for cryin out loud i can drop 700 bucks on a pocketbike motor that is 47cc and 10hp The law states cant put out more than 1/4HP which is why we are stuck with pissy 200watt the STOCK STANDARD china gurl 49CC motors put out over 1hp for gods sake, as per usual our laws are lagging behind the rest of the world, i vote for a sensible 750watt legal limit like in USA a professional cyclist is able to generate (not sustain for long though) 750watts But the powers that be will drag their feet like they do on everything else no doubt. I don't care the can arrest me and throw me in jail might get some welcome publicity over it even LoL in meantime my photochopped 1000wat to 200watt sticker will suffice, as a matter of fact seeing im a paraplegic the trike is a mobility device as such is not covered by the bicycle law but the mobility scooter law which states NO SIZE LIMIT on motor BUT thereis a catch, can't ride on the road (fine i dont out of my neighbourhood anywayz) and can't exceed 10km/hr WHOOPS..."i got nice run off the hill officer"..."I clocked you at 40km/hr going up the hill sir..." :-|   LoL

Range...i have never run the batteries flat buddy, i would guess 10-15km/hr up here though due to the terrain. I can make it from Lesmurdie (im at the far end of Lesmurdie near Mazenod College) too Kalamunda and back 2 times on a charge so it is more than adequate for
what it was designed for ie. get me to Kala shops and Pub LoL....

Cheers for the interest

KiM

htial
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Post by htial » Tue, 15 Sep 2009, 23:57

I should just mention that one of the photos sets has an extra "h" in the "http" part and won't display...

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Post by F&P » Fri, 18 Dec 2009, 02:55

That is really a beast, well done, especially the touch with the wide rear wheels.

F&P
Matt

F&P Matt

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