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Road Legal StreetQuad conversion

83459 Views 216 Replies 24 Participants Last post by  Firehuntah
Hello!

Been lurking this awesome forum for nearly 2 years now, gathering information about all the components for a conversion and I think it's time to slowly get started on my first project.

First let me introduce myself. My name is Rob, I'm almost 24 years old and I live in the Netherlands. Currently I'm working as a maintenance mechanic for a cable company. I'm really into cars and anything else on 4 wheels, always have been. It's only since 2 or 3 years ago that I really started to like electric vehicles though. I think mainly because of the performance of the Tesla Roadster, never thought an electric could go so fast while not emitting anything. Little did I know back then. :)
The more I started researching electric cars after that, the more I started to like them. And now I'm at a point where I really don't want anything else than electric anymore. Sadly for my job I'll still have to stick to gas since it's a company car. But for driving in my free time I'm planning to get a quad bike converted to electric. And maybe in the future a car when I have some more experience.

So, moving on to the project with the quad bike I'm planning.

My skill level: Not that great, but I know the basics since I studied for car mechanic for a few years, I just ended up doing something else. As for fabrication, I don't know how to weld and stuff like that so I'll probably have to get motor mounts and battery boxes made. Or I could start learning how to weld. :rolleyes: Fabricating small things like copper plates for battery connections shouldn't be a problem though, have the tools for that.
Range: I'd like to get a range of at least 80km (50 miles) at 80% DoD, which I think should be possible since the quad bike I'm looking for weighs only 170kg (375lbs). Not sure how aerodynamic it is, it is pretty low to the ground though. Make and model of the quad bike is a JLA Loncin Streetquad in case you want to look it up since I don't have any pictures myself yet.
Performance: The top speed has to be between 85-100kmh (53-62mph). Also want decent acceleration, compareable to the original 250cc motor. Not sure how fast that would be though since I haven't driven on one yet. Max 8-10 seconds to top speed I guess.
Budget: I want to spend around 6.000-6.500 euros ($7.800-$8.400) max for the conversion. Any more than that and I'm not really sure if it'll be worth it for a quad bike.
Parts I've already considered:
GBS 12v 100Ah pack x4 (for 48v system) + BMS and display
LMC LEM-200 127 Motor (contacted LMC, they suggested I use a LEM-200 D95B instead but I'm not sure which would be better)
Alltrax AXE4844 Controller (LMC suggested the Sigma PMT445 if I'd go with the D95B Motor)
Curtis PB-6 Throttle
DC DC Converter (not sure how much watt I would need)
Charger (not sure yet, needs to fit in the small frame where the gas tank currently is, do want to get a full charge within 6 hours or so though)
Cables/Connections/Mounts

With these parts I expect to be around my budget price, I'm just not sure if these parts will be good enough to get the performance I want, especially with a 48V system. Was looking for 72V as well but I'm not sure which batteries I could best use for that since I can't really fit 72V with prismatic lithium cells. The A123 pouch cells would have been nice but I guess it's not really possible anymore to get them from a reliable source.

Also, being in the Netherlands it's pretty hard to find good parts for the conversion since there has to be a CE mark on all of the electric components I'll be using to avoid an EMC (or EMI) test for road approval, which would cost 1.300 euros ($1.700).

That's about all I know right now, hoping to get some feedback on the parts I've chosen. Or suggestions for other parts that are better suited and not too expensive. :) And if it's possible to do this conversion with a 48V system or I should go higher to 72V with different batteries.

Thanks in advance!
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So it's been a very long time now since I was active here in this forum. Quite sad really since I always enjoyed following all the projects here. :p But I might be back now for a while. I'd like to start again by giving you all an update of the project. :)



Time really flies, it's already been over 2 years since my last post here. I think it's about time I give you all an update. And what better way to do that than by sharing a video of a nice sunny ride in autumn. As you can see the quad bike and me are still doing well. :)

https://www.youtube.com/watch?v=aVIzUBP8ixg

Since I solved the temperature problem 2 years ago I didn't run into any real problems anymore. I've just been enjoying all the rides I could do with it without any needed maintenance whatsoever.

But part of this no maintenance has to do with a pretty sad problem, the range. You'd think that in 2 years time I'd have quite some mileage on it, but that's far from the truth. The problem here is that, with my current battery pack, I was expecting a range of about 60 miles / 100 km. In reality I'm not even getting half of that, maybe if I'm very conservative.

So the result is that I can't really take it out for long and also can't even get to work with it. I guess you could say it's a miscalculation for the capacity of the battery pack that I needed. But it actually is pretty close in terms of capacity to some electric motorcycles that get much further on a charge. What I didn't really account for was the enormous drag / wind resistance you get on a quad bike while driving at high speed on the road. And ofcourse the rear tyres being connected by a solid axle instead of a differential doesn't help for the range either.

This will one day be fixed by upgrading the battery pack to a larger one. But this will be quite a costly upgrade and right now I have some other priorities that will also cost me money. So for now it'll have to stay like this while still enjoying the short rides around town. Lets just say it's not a problem that can't be fixed, it's just that it is the most expensive problem you can have with an electric conversion. ;)

Other than that it's all been good but some parts did get swapped out. One of them being the Trailtech Striker tachometer which unfortunately broke down not too long ago and it was just outside of the warranty period. But I have a new one now and it's been working great again. I also replaced the Tracopower DC/DC converter with a Sevcon. I needed a little bit more power since the Tracopower couldn't really handle the load without getting very hot. Again, no more issues after replacing. I've also made some small changes to the 12V electric system, mainly to make the charging process a bit easier and to remove some components that weren't really being used anymore. But that's about it. The only thing I'm still thinking about is converting the chain to a belt since the chain grease is hard to get off the beautiful white frame. ;)

So that concludes my update. I'm not sure but I think it might be a while again before you see another update here. Probably next year around this time there'll be an update about the other priorities I was talking about but I can't really say too much about that yet right now.



Btw, I also noticed that all of my images are gone here thanks to Photobucket. In case anyone wants to see the history of this project, you can check my blog, it's all still available there. :)
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Btw, I also noticed that all of my images are gone here thanks to Photobucket.
I installed the "photobucket embed fix" extension in my Chrome browser, so I still see all of your images :) ... for now.
I installed the "photobucket embed fix" extension in my Chrome browser, so I still see all of your images :) ... for now.
That works perfectly indeed, thanks for that. Wonder how it works, if it's that simple couldn't it just be implemented on all of the affected forums so you don't need an extension to view the pictures? :D Cause as it is now, people without that extension still wouldn't be able to view the pictures. It is easier to replace them all now that I see them though, maybe if one day I have enough time.. :)
Wonder how it works, if it's that simple couldn't it just be implemented on all of the affected forums so you don't need an extension to view the pictures? :D Cause as it is now, people without that extension still wouldn't be able to view the pictures. It is easier to replace them all now that I see them though, maybe if one day I have enough time.. :)
This is the thread from the forum administration:
This is another discussion of the issue:
Great result Firehunta, You can be proud of your EV. You mention the disappointing range = air resistance. Do you have an energy efficiency number for Quads, like the very general number for EV passenger cars = 0,170 kWh/km ?
Great result Firehunta, You can be proud of your EV. You mention the disappointing range = air resistance. Do you have an energy efficiency number for Quads, like the very general number for EV passenger cars = 0,170 kWh/km ?
Thanks! And I sure am. :) This was my first project and I didn't expect it to go as well as it did. While it did take much longer than I thought it would the end result is really nice. Especially that it's road legal, that was probably the hardest part to achieve.

The air resistance I assume is the biggest cause for the range being so low, since I've tried with a few different setups, like removing some of the wider and flat (as seen from the front of the quad bike) fenders and the range improved. Not enough to give up on the looks of those fenders though, so they're back on. :p As for the general kWh/km for quads I have no idea. I have a lot of data from my Soliton but I'm not really sure how to calculate the kWh/km with that right now. All I know is that in order to keep riding at 80 km/h for example it keeps pulling around 220 amps with my 76.8V nominal pack (24x CALB 60Ah). If you could help me out with the calculation for that then we'll know the kWh/km I guess. ;)
Yeah it's quite bad. :D Some have even said that quad bikes have more air resistance than a truck. Bit hard to believe at first but the numbers in my data don't lie I guess.

The thing with cars is that it's a complete body where the air gets pushed around it. With a quad bike there's a whole frame where the air goes through all of the different tubes, also a lot of fenders and as seen from the front a big flat surface of the battery pack. And then you still have the wheels without any cover on them and ofcourse myself not being very aerodynamic. :p Many factors that really push up that air resistance. There are definately ways to improve it, but would it still look like a real quad bike then? ;)
The drag-coefficient Cw of a Quad is (probably) dramatically high. And with frontal area (not much smaller than) a passenger car, your quad must consume more energy than a modern car on the highway. Tonight I consumed also 211 Wh/km with Nissan Leaf, while driving 123 km/hr continuously. The energy-efficiency advantage of the Quad must be at the low speed- city travel - cornering... when acceleration of mass is the determining factor. Advice: avoid the highway, don't travel at constant speeds and accelerate like a lunatic and you will enjoy your energy-efficiency most.
Yep, that's true. The low weight definately helps with the range when accelerating slowly and driving at lower maximum speeds. But well.. I'm not that kind of driver/rider really. :p I even built in an eco mode for this but I haven't touched the button for it even once after the first test. :D

Anyway, I don't go on highways since the quad's max speed is 'only' 95-100 km/h. I wouldn't feel safe with cars blazing past me every second. But unfortunately to get from one town to another I always have to drive/ride on 80 km/h roads. So I can't just keep going 50 km/h for example to get more range out of it.

I just need a bigger battery pack so I can still have all the fun and get a bit further while doing so. :p But next year something else is coming along that will cost quite some money so the quad bike will stay as is right now, just have to enjoy going around town with it for now. :) But after that I will definately put some upgrades on this quad bike.
Hi
How much power are you using?

My "Device" uses 26 kW at 100 kph and about 7 kW at 50 kph

Or at least it used to use - I've made some modes to reduce the aero drag but I don't have an accurate ammeter at the moment
It's around 17 kW at 80 km/h and I think around 7 kW as well at 50 km/h, don't have as much data of me going 50 km/h for a long time. :p So yeah.. it's not too bad at lower speeds but at higher speeds it really eats away the range. ;) The battery pack is only 4.6 kWh though, couldn't really fit any more CALB CA60's in the frame. So I either have to wait for smaller cells or modify the frame so I can create more space for batteries. Or ofcourse both for the best result. :D
My "Device" uses 26 kW at 100 kph and about 7 kW at 50 kph
It's around 17 kW at 80 km/h and I think around 7 kW as well at 50 km/h...
I did a quick fit of each set of data assuming that drag is a function of a constant force (and so power proportional to speed, due to rolling drag) plus a force proportional to the square of speed (and so power proportional to the cube of speed, due to aerodynamic drag). They're not just matched at 50 km/h, the power grows in the same proportion, so to the precision of this approximation these two vehicles would have the same power requirement as each other at any constant speed.

I would rather sit in the Device than straddle a quad, but that's a personal preference. ;)
So another year just went by again. I did say in my last post it might take a while but here I am again. :) I unfortunately haven't been able to ride much this year due to some health issues but thankfully it's slowly getting better. So when the weather was nice again last weekend I just couldn't resist to go out for another ride. Ofcourse I have some footage again, this time I went for the onboards, both front and rear. Still think this is more fun to see than helmet cam, at least for myself to see everything moving and check up on things. Like how I now know that I have to adjust my chain tension a bit. :D

https://www.youtube.com/watch?v=dUbjaIn7L4g

I went for another ride today to visit some friends, still have to edit the footage since it's way too much to put in one video. So more on that soon. :)
Last week I had another ride which was actually the longest so far. I went to visit the company that helped making the aluminum parts (Geraets Metaalbewerking). I promised them a while ago already that I'd come there to show the quad bike but just never got around to it. But now was the time to finally do it.

Pretty much the whole ride was on Eco mode to make sure I could actually get there. I was a bit worried since the range of this quad bike is still pretty low at only 30-35 km (18-21 miles). The distance to there is about 23 km (14 miles) so I went a bit easy on the power. In the end though it doesn't seem to make that much difference if I use Eco or Sport mode. Power is limited in Eco mode but since it takes me longer to get to a certain speed I still end up using around the same power as when I get there quickly using Sport mode.

Thankfully I could get there without a problem with still around 30% battery left. On the way back I was a bit less conservative and used Sport mode a few times. Again I had about 30% left. The way back was a bit shorter though since I could take a small shortcut. Ofcourse I did have to recharge while on visit, took about 2,5 hours from 30% back to 100%.

This was a really fun day for me, spent a lot more time than usual on the quad bike and it was really nice to show that company the quad bike. They only saw the aluminum parts that they made for me back then. Now they could see them mounted on the quad bike and the actual result of the project itself. :)

There were also 3 firsts during this ride, first time riding through a 'bigger' city, the first time on an highway (100 km/h / 62 mph) and also the first time actually making it to 100 km/h (62 mph). It was behind a truck and going downhill but it counts! Both riding in the city and on the highway were pretty weird but fun at the same time. Ofcourse I also had to make a video of it again, think it's also the longest video so far. :D

https://www.youtube.com/watch?v=42G1i_8DeBE
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Hoping this is still active, @Firehuntah since your quad is 48V, did you have to do the EMC test on RDW?
Hoping this is still active, @Firehuntah since your quad is 48V, did you have to do the EMC test on RDW?
Not really active here anymore but I got a notification so that helped. 😉 The quad bike is actually running at 72V, not 48V. At the time I got my quad bike approved an EMC test was not yet necessary since all the components I was using (most important, the controller) was already EMC approved. I do know that after the approval of my quad bike things have changed at the RDW and I believe an EMC test is necessary for every EV conversion now, no matter which components are used. Maybe I caused that by trying to get my conversion approved, sorry. 😅 Though I'm not sure if the voltage actually has an effect on this. It's been quite a few years since I last checked their regulations.




Maybe nice to post a quick update on the quad bike now that I'm here. Ever since completion of it in 2015 I've been able to ride it trouble free. I only still did an upgrade on the DC/DC converter since the old one I was using was just too weak.And had to replace the tachometer since it died on me. Other than that, I've seen no issues at all and has been very reliable.

At least.. up untill Winter now. Have always been used to leaving the quad bike for a couple of months when not driving and the battery pack would hardly even drain. So now these last few months I again hadn't been driving it and figured I'd charge it again. Unfortunately though, this time the battery pack did drain quite a lot, even though nothing changed and nothing was left on. The pack was only showing around 18V. This was like 2 weeks ago and didn't really have time to actually work on getting those batteries removed and inspected yet. I do suspect those batteries are dead now though. While it might be possible to recovery them, it's risky and probably they won't have anything near full capacity anymore anyway. So.. for now the project is dead. But at some point in the future I'm sure I'll look into doing a battery upgrade and getting it operational again. Been wanting to do a battery upgrade anyway since the range was pretty low, only about 30-50km (18-31 miles). Quad bike has a huge amount of drag. 😬 When the time comes, I'll be sure to post an update here. 😃
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