[ZX-E]

My roommate (Alex, a4111) and me have been planning a conversion since January. I want to start a thread on our Kawasaki ZX-9R conversion. The bike is sitting in our garage right now with a warp 8 inside the downtubes. I also have 200 headway p cells sitting in my room. We're looking at a 156 volt setup using a Synkromotive controller.

This bike is going to be built for performance and to try out a single monster motor instead of two or three smaller ones.


Here's the thread for the speed calculator I originally made to find the ideal gear ratio for the ninja project and a Rav4 at evcomponents:
http://www.diyelectriccar.com/forums...tor-36920.html

I estimated a 4 second zero to sixty and a 13 second quarter mile for the bike at 144 volts and 700 peak motor amps.



I'll post questions we have about the project here if you guys don't mind .

[Big-Foot]

Just got my 93 ZX6E Donor yesterday....

Mine will be a 72v DC-Series system with AGM batteries (Optima Yellow).

I hope you have access to someone who can weld aluminum.

[ZX-E]

Sweet! How much did you get it for?

I do know a guy who does aluminum welding; albeit 5/8 thick aluminum, so it's going to be tricky. We're planning on using the motor mount design and build process as our senior Mechanical Engineering project.

[frodus]

note: 38120P cells are the 8Ah Headway cells, for people that didn't know.

Can't wait to see it Rich, its going to be a fun project.

[Big-Foot]

Originally Posted by ZX-E

Sweet! How much did you get it for?

I do know a guy who does aluminum welding; albeit 5/8 thick aluminum, so it's going to be tricky. We're planning on using the motor mount design and build process as our senior Mechanical Engineering project.

I've got a few hundred in it. The bike's never been down and has less than 20k on it. New tires and brakes - plastic is all in pretty good shape.

5/8" thick aluminum - wow... That would take quite a welder to do that...
My Miller TIG will only go up to 200 amps and that's about 1/4" thick Aluminum that I could weld.

I'm going to be looking into other battery technology than the AGM. I would really like to get to the point where I could go 50-60 miles at 60 MPH.

[ZX-E]

We're putting bearings inside the aluminum. It's going to be pretty complicated. But what I'm really not sure how to do is mount the batteries to the frame. If there's a will there's a way right?

At 60 mph with 196 8 amp hour cells I'm looking at about a fifty mile range . They aren't the most energy dense cells, but four of them in parallel can do 500 amps (battery side) easily at about 15 C which is all I need for peak power motor side.

Here's the electrical portion of a calculator I made in excel that I used to come up with those numbers:

[Big-Foot]

Originally Posted by ZX-E

We're putting bearings inside the aluminum.

You lost me on that one...

It's going to be pretty complicated. But what I'm really not sure how to do is mount the batteries to the frame. If there's a will there's a way right?

Build a carriage out of angle aluminum or steel. If steel - just bolt it up to your frame.. The fuel tanks are larger than you might expect if the bottom is cut out...

At 60 mph with 196 8 amp hour cells I'm looking at about a fifty mile range . They aren't the most energy dense cells, but four of them in parallel can do 500 amps (battery side) easily at about 15 C which is all I need for peak power motor side.

Here's the electrical portion of a calculator I made in excel that I used to come up with those numbers:

500 amps is a BUNCH...

[ZX-E]

Yea I should have clarified. The chain on the motor goes to an intermediate jackshaft mounted on bearings, the shaft has another sprocket on it that drives the wheel. This is for a few obvious reasons. One, so the warp 8 doesn't stick out of one side of the motorcycle half a foot. Two, so the motor isn't right where your feet are. And three, so we can keep the drive sprocket right where it originally was. You can see screenshots of a 3D Solidworks drawing of it on the project website: www.hvbikes.com. (The website is kind of a mess right now, but I'll pull it together in the next few months).


Yea and 700 amps motor side!

[ZX-E]

[Qer]

Originally Posted by frodus

note: 38120P cells are the 8Ah Headway cells, for people that didn't know.

When I googled on 38120P I got 10Ah, 10C nominal and 20C max. Pretty ok I guess, but 200 Amps sounds low. On the other hand, maybe 200 Amps isn't low for an MC...