1st split panel

First split panel has been detailed with B-surfaces to match fixing points. Yes, I need to get a load more completed. But, so chuffed to get the first one out of CAS and into the 3D printer. After looking at the model and the new part I think the only additional part will be an…

Control panel v2 installed

Long time no post. Have recently replaced the brake cables, one was too short and was twisted, think it effected brakes. Also managed to change the handlebars to the white set pictured in renderings. I have installed the v2 control panel that will accommodate the covering covers for the bike and now holds the contactor….

Switch panel v2 & cover

Have finally printed out a solid version of the switch panel and cover. Looks okay for a first bash but would like to make some amendments to some parts to increase the quality. All new part fi together perfectly. Need to find a rubber strip about 1-2mm thick to place in the channel where the…

Security

I have decided to take some measures to give the bike a small level of security by locking up the activation switches. I have designed a cam lock into the switch cover. Quite simple really and there is enough purchase at the back of the new switch panel to hold the lever securely. Ultimately this…

Surface update

Have worked on some surface updates that include a load of details that aren’t so visible but are needed to make printable parts that fit to the frame securely. The surfaces are still WIP so still a shed load to finish. Main area to date have been the formation of : – The new blistered…

Control Panel v2

The first switch panel was great as a mule to test the system but it didn’t match the upper panels so it’s time to make a new design that works better with the upper panels. Once I have finished this i need to make a flip-up cover to give access to the panel and make…

Cover redesign

3 issues that seem important at the moment: Access to the control panel – Currently thinking of a hatch over the control panel that hinges from the front (pivot point arrowed in red). Potentially this could be locked. Air flow to the bottom of the controller – Marked in green thinking that it would be…

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…

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…