Need to start mounting some of the components that are just hanging around at the moment. I have put something together in CAD quickly and spent a bit of time with the printer. Have tried a new material rPETG that has a substantially higher temperature and water resistance and has excellent ductile strength making it…
Category: design
Isolator carriage v2 printed
I know I should be used to it by now (after all I see it happens all the time in University and in the design industry) but it still amazes me that I can print designs into reality that only exist on a computer. Anyway, I managed to push out a rough print overnight to…
Isolator carriage v2
Have made some changes to v1 design of the isolator carriage. A bit more cable management and some amendments to the BMS to ensure the charge input cables are orriended correctly, etc. Need to print the design to double check it maybe get some advise of the management of the cables. Currently the high and…
Isolator carriage v1
Having had some small issues with dimensional accuracy I have finally started to get some results on the bigger prints and I am finding new uses for the printer. Originally I planned to stick the BMS, charger, and precharger components onto a thin board with 3M double sided tape to isolate it from the batteries….
300mm cuts
Have started to think about the opportunity to 3D print panels rather than metal form them. The more I think about it the more it makes sense. Plastic doesn’t conduct electricity, useful trait on an electric bike… and the production will be easier for my CAD skillset. Having had the printer for a while I…
Rear battery box cover v2
I have spent an evening making some changes to the design of the original battery box to give better clearance for the cables I originally planned to through the bottom of the box because that is where the BMS used to be but now that it is better placed above the battery amendments need to…
Mock under bracket
Interesting to see the growing form of the battery as a whole with the under bracket mocked up in card. All seems to be good. The contactor can be easily removed and replaced and when in position both the contactor and the DCDC convertor clearance is good. On issue is the cable routing. The high…
Underside mounts & protection
Started to think of mounting points for the lower covers and extra protection for the contactor and DC/DC convertor components under the battery case. Decided to combine them. thinking it needs to be quite strong so some folded 3mm alu will make for easy fabricate but maintain strength. The extra thickness should make the mounting…
Step back and see…
Great light today, thought it word be a good opportunity to take a step back and have a look at the old bike to observe it from a distance. Being stuck in the garage I’m often working up close and never get to see how it looks from a ‘normal’ street level perspective. Social media…
Shiny lines
I have some shiny new stainless steel custom brake hoses from OHA motorsport. I know this because that is what it says on the bag — useful sticker. Fitment seems good in general. There is a bit of slack in the rear line. It was ordered with extra length because there are still questions about…
An electrifying life on two wheels... 