Wiring…

Okay, time to make a start on the cable loom for XJ600e, finally. Bit of a boring post but an important one because once all is sound with the wiring then finally the panel design can start with the assurement that the packaging for the powertrain is concrete. This means less changes to the final…

r/e PLA (recycled/eco PolyLactic Acid)

To help guide the project along the lines of sustainability and ethics circular design I have been on the hunt for recycled/eco filaments. Ultimately I would like to find a reclaim company that can take my waste prototype material and offer maybe a discount towards future material, etc. This is hard to find as often…

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…

First 3D print

After 23 hrs (I sped up the printer) the rear battery panel is complete. it fits the main case like a glove. However the top case cover needs some amendment. As the print is probably more accurate than the metal bend. I will use it to finally shape the metal cover. As for my virgin…

3D additive prototyping

To help the prototyping phase move along more fluently I have acquired a 3D printer. It was useful to use a print shop but costly. Working sheerly on cost and the fact that 3D printers are so cheap nowadays it is more economical to make plastic parts myself. I have more control concerning quick changes…

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…

Alu under bracket

Managed to get my hands on a sheet of 3mm 1050 Aluminium (a test of sheer will if looking for a decent price in these COVID times) so I could hack and fold the under bracket in a hard material. I haven’t used 3mm material before so I was a bit worried about folding and…