Voltron, the Electric RG!

Post up a thread for your EV. Progress pics, description and assorted alliteration
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jonescg
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Voltron, the Electric RG!

Post by jonescg » Fri, 22 Jan 2010, 21:08

Hi guys and girls,
This is the start of my worklog on the Electric RG. I have made substantial progress since starting, so expect a bunch of pictures to slowly populate the page.

This is the chassis as I bought it from Two Wheel Wreckers in Osborne Park:
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Clearly the frame and wheels looked pretty dull, and half the parts were missing :)
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I bought some second hand brake calipers and discs from a wrecker in Sydney, along with the top fairing. I don't think I'll use the top fairing, rather go for something original:
Image

I cleaned up the calipers and placed an order through WEmoto.com for new caliper seals etc:
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Complete overhaul of the forks was necessary :(
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New master cylinder too...
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Agni 95 B motors are here!
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Chassis is all back together now:
Image
Image

This is where they will sit:
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With stacks of room for batteries :)
Image


So that's a good 6 months work there. I'm getting the motor mounts laser cut now, and I found out my 428 pitch sprockes will be in next week. Goodwill Engineering will weld the mounts up for me and I also hope to have the motor crash guards done by then too.

Coming together!

CHRIS

PS I have registered my team (Voltron) in the TTX-GP :D All I need now is the money... :(
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woody
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Post by woody » Fri, 22 Jan 2010, 21:14

Voltron is such an awesome name. How much money do you need for TTX-GP?
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jonescg
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Post by jonescg » Fri, 22 Jan 2010, 21:56

I checked and the entry into the UK eGP is 350 GBP. The fastes 6 riders from this will be eligible to ride in the IOM in July (I think).

But getting my machine and myself over there is the biggest cost :( Worth checking out anyway.
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antiscab
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Post by antiscab » Sat, 23 Jan 2010, 11:24

looking good, when its running bring it along to a meeting :D

Matt
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acmotor
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Post by acmotor » Sat, 23 Jan 2010, 17:07

Chris,
Firstly... how did you get clearance to put the project in the lounge room ???? Image
Second... nice choice of bike. Image
Third... what batteries do you plan on ? Maybe sponsorship by Lithbattboss ? Though you are in A123 territory. Those twin agnis will suck some juice. edit: of course you could sell your house and go LiPo.Image
Woody, are you going to run some numbers ? Image

Perhaps make a presentation at a Perth branch meeting and call for pledges. I'd be in !
Last edited by acmotor on Sat, 23 Jan 2010, 06:22, edited 1 time in total.
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jonescg
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Post by jonescg » Sat, 23 Jan 2010, 20:38

Hehe, the GF is happy to support my hobbies (motorcycles, racing, e-motos) and I supoprt hers (sewing, jewelery making and cooking). It's a win-win ;)

I have plans for LiPo - about 80 ah worth of them, at a nominal 105.6 V. I have budgeted about $6k for cells. The motor only spins out to 6000 rpm, so I don't want to push it past 90 V. I might need a redline indicator :D

I'm keen to join the AEVA too; I'll take any support to get this baby up and running, and show the world what backyard Aussie ingenuity can come up with.
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Voltron, the Electric RG!

Post by AussieJester » Thu, 28 Jan 2010, 23:06

Good to see the worklog up on AEVA mate :-)

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Post by antiscab » Thu, 28 Jan 2010, 23:26

i forget, are those agni motors BLDC, or just straight DC?
if BLDC, most BLDC controllers can be programmed to limit motor rpm..

Matt
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jonescg
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Post by jonescg » Fri, 29 Jan 2010, 00:57

Nope, these puppies are brushed. The brushes are good for 110 Volts, but the motor will probably fly to pieces at >6000 rpm. Probably a good thing :)

My motor mounts were cut out by Action Laser Cutting Image Very happy with the results. Goodwill Engineering have the job of putting it all together, if my sprockets ever arrive...
Image
Getting there.
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jonescg
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Post by jonescg » Mon, 01 Feb 2010, 18:45

Picked up a tank yesterday. I will make a mould of it and try to re-cast it in fibreglass or carbon fibre. This way I can make it a little taller and a little wider to fit the batteries underneath, and it reduces the weight by about 2.5 kg.

Image
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Richo
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Post by Richo » Tue, 02 Feb 2010, 07:26

Any ideas how much power you wil get from the two motors?

EDIT: Oopps forgot to ask how much power (manf spec) the bike had originally too?
Last edited by Richo on Mon, 01 Feb 2010, 20:27, edited 1 time in total.
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jonescg
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Post by jonescg » Tue, 02 Feb 2010, 18:20

Peak power from both motors is probably around 60 hp. Not sure how that will translate into rear wheel power till I a) build it and b) put it on the dyno.

Original power was 45 hp from a 250 cc parallel twin two-stroke.
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Post by jonescg » Tue, 02 Feb 2010, 23:07

Okay, for those of you in Perth who are looking for sprockets and chains, go no further than http://www.motionindustries.com.au/Default.aspx

These guys stock 19 mm hubs perfect for the Agni motor shaft. Sprockets Oz can go blow!
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Post by jonescg » Thu, 04 Feb 2010, 02:07

I realised I will need to counter-weight the motor on the left hand side with something heavy, motor-like and ... well it finally dawned on me that the other motor might as well hang out the right-hand side!
This leaves some valuable room to put $6k worth of LiFePO4 cells too. A bit of cardboard aided design, with the Mrs' knitting needles for the extended drive shaft and frame attachments :)

Image
Image
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Post by Electrocycle » Thu, 04 Feb 2010, 02:41

yep, definitely hang them out the sides :)
It seems to be a well proven setup, and both motors will get good air flow for cooling.
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Post by jonescg » Thu, 11 Feb 2010, 20:00

Image

Sprockets Oz in Melbourne got my sprockets built after 3 months. It includes the Christmas period, but still a bit slow. $145 all told.

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jonescg
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Post by jonescg » Mon, 15 Mar 2010, 17:37

A variety of sprocket sizes means different riding characteristics for different circuits
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Bar ends to make it legal :)
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Starting to take shape...

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Some carbon fibre bling :)
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Last edited by jonescg on Mon, 15 Mar 2010, 06:38, edited 1 time in total.
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Post by antiscab » Mon, 15 Mar 2010, 22:55

looking good Chirs :D
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Post by htial » Tue, 16 Mar 2010, 00:14

Looks like it's coming along really well...

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Post by jonescg » Sun, 28 Mar 2010, 16:13

Image
Image
Image
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Post by Thalass » Mon, 29 Mar 2010, 02:10

Looks good with the fairing on! haha
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Post by a4x4kiwi » Tue, 30 Mar 2010, 16:34

Looks great.

Do you have any theoretical performance figures?

0-60?
0-100?
400M?

BTW you might be interested in entering the following event in Dec.
Formula Xtreme.
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Post by jonescg » Wed, 31 Mar 2010, 20:38

Don't know at this stage; still waiting on my batteries. But I would hope to have a top speed of at least 150 km/h (might take a month to get there) but the 0-100 should be pretty good.
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Post by jonescg » Sun, 04 Apr 2010, 02:51

Well what a productive easter saturday :)
I have a bunch of pictures - if they don't fit your screen you can right-click save as open blah blah.

I finally got around to building a decent workbench in my new (slightly storm-damaged) shed :)
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Even got room for a vice.
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Now, the bike :twisted:
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One with the lovely Katherine, making the picture 100% prettier.
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Other side
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I have a problem with clearance up here - the handlebars need to go lower to clear the fairings, which is easy, but this reduces the travel of the suspension. Given I'm adding 20 kg to the kerb weight, I really ought to get stiffer springs, where the travel is reduced but stiffer.
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I bought this to tidy up the fairings since the grinder does a rough job. Also, the carbon mudguard can be modified to suit.
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This is a bit of a worry :lol:
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I still need to make brackets to suit the fairings. Could be a bit of dicking around, but I'm sure I can come up with something. The rear ducktail is still a bit of a mystery to me. I feel that if I put it on, the bike will look like it's pants are too big. It looks like a bucket racer anyway... might not be so bad.

Fun times... :)
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Post by jonescg » Mon, 12 Apr 2010, 06:03

Hi All,

Well today I finished up the fairings to the point where they are self-supporting. Everything is in place so I can make a list of things to put finishing touches. This is the bike as she stands now:

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This is how I'm holding the fairings on at the moment. I'll get some more correctly sized bolts later on.
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I'm most happy about the way I got the carbon mudguard to go on. I want to eventually remove the anti-dive units since they don't do anything. This would alow for the thing to be fixed with a bolt at the base.

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Lots of room for batteries in there. It'll be tight but I think we're OK.
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This is the front fairing bracket. Pretty agricultural, but it works. I need to put another bolt and strap of steel out to the fairings to steady side-to-side movement. There are also some spacers which point out from the fairings where folks would normally attach an Oggyknob. I can extend these and put a bolt in there too. Then it's not going anywhere :)
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I also need to find room for the cycle-analyst computer and speedo / tacho / battery management signals etc.

Yep - you can slide the bar down and tighten the crap out of the pinchbolt Image It could be a bit neater, but it worked.
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Looking good Image Bring on the batteries!!!!!
Image
Last edited by jonescg on Sun, 11 Apr 2010, 20:08, edited 1 time in total.
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