I always finish my projects like this by going out and taking some glamor shots.
But first lets get to what everyone has been asking for:
- Top speed: 55mph (88kph)
- Exactly what I was expecting and what I planned for
- Range: 20 miles (32 kilometers)
- Exactly what was estimated
- Without regen braking activated
- That's on used, old batteries. The same batteries but new would probably get 30 to 35 miles.
- Charge time: not really sure, no more than 5 hours I would say
- I'm using a really really small charger, only 3 amps. The energy draw is equal to 2.5 100w incandescant light bulbs.
- I could upgrade to a 5 or 6, or even a 10 amp charger if I really wanted to, but 10 amps might blow the fuse inside the battery enclosure
I need to program the motor controller again and activate the regen mode so I can see how many more miles that would add to the range, but my wife is learning how to ride it (the bike is for her) and that would just make it more complicated I think.
Ok now for the photos!
How much did it cost?
| CA160 w/ seized engine: | $500 |
| Emblems: | $30 |
| handlebars, grips, horn: | $100 |
| tank side covers: | $56 |
| QS 4kw hub motor | $335 |
| Kelly motor controller | $228 |
| disc brake | $30 |
| twist throttle | $5 |
| shipping for motor etc | $218 |
| cart jig thing | $75 |
| antique license plate. | $55 |
| primer: | $20 |
| tires: | $152 |
| speedometer cable: | $18 |
| tank rubber cusions: | $40 |
| spare key: | $14 |
| battery cells: | $225 |
| ^^ shipping: | $55 |
| tubes: | $53 |
| headlight: | $27 |
| clear paint: | $40 |
| wire connectors: | $23 |
| horn button: | $15 |
| various things: | $130 |
| 2k urethan paint: | $110 |
| wire and tape: | $50 |
| sheet metal & tools: | $200 |
| dc-dc converter | $22 |
| BMS | $65 |
| contactor & accessories: | $114 |
| ^^ shipping: | $30 |
| charger: | $60 |
| connectors: | $20 |
| more connectors: | $40 |
| handlebars: | $50 |
| seat: | $50 |
| handlebars (again): | $71 |
| inner tube: | $20 |
| hand controls: | $40 |
| distribution blocks: | $35 |
| crimper tool & connectors: | $35 |
| contactor: | $70 |
| turn signals: | $60 |
Total: $3,586
Pretty cheap compared to a Zero or even a Sonders electric motorcycle. But then again I get half the range as a Sonders.
Parts List
EV Components:
used LG pouch cells
15ah 3.6v LG Chem pouch cells (when new)
200mm x 260mm x 8mm - or - 8” x 10.5” x 3/8” (with the plastic cases)
need to cut these 4p modules to two 2p packs:
https://batteryhookup.com/products/lg-c ... -stackable
20s2p = 72v 30ah and 90amp continuous discharge rate (3c)
but if 2/3 capacity left, then only ***20ah and 60amp discharge rate***
40 cells total, a four pack is $20, that’s $200
max voltage: 84v
min voltage: 50v
peak discharge current: 150amps ???
6.5kw ~= 72v x 90 amps (continuous discharge rate)
4.32kw = 72v x 60 amps (comtinous discharge rate @ 2/3 capacity)
...
range estimates:
at 30mph, expected consumption will be approx. 50 Wh/mile, or 20 miles per kWh
1800 Wh / 50 Wh/mile = 36 miles
however, others say it is 8-14 miles per kWh
1.8 kWh * 8 miles / kWh = 14.4 miles
1.8 kWh * 14 miles / kWh = 25.2 miles
and yet others say 100Wh/mile or 10 miles per kWh
1800 Wh / 100 Wh/mile = 18 miles
....
motor:
http://www.qs-motor.com/product/4000w-s ... otorcycle/
maximum motor current at 72v: 90 amps (as stated in specs)
continuous motor current at 72v: 55 amps (4kw / 72v) (61a stated in the specs)
...
controller
Kelly KLS7245N
90 amp continuous and 270 amp peak (phase current, which approaches battery current as RPM approaches max speed)
...
DC-DC converter:
20w from amazon
https://amzn.to/3M3UFV5
BMS:
DALY 100amp 20s 72v
Charger: https://amzn.to/3rnosi5
Contactor:
https://www.te.com/usa-en/product-1618387-3.html
Kill switch: https://amzn.to/3NXKkKH
display: 72v charge meter from Kelly
Connectors and misc:
charger port: https://amzn.to/3BXeDfm
battery enclosure connectors: https://amzn.to/3fwSg93
wire connector kit: https://amzn.to/3UZbnc3
terminal covers: https://amzn.to/3ydIU8J
Restoration parts:
tank emblems
tank bushings/cushions
tank side covers
tank knee pads
speedometer cable
handlebars
grips
tires
front brake lever
front brake cable
rear brakes
ignitition key
turn signals
swing arm bushings
speedometer lightbulbs
headlight bulb
horn and button
handlebars
seat
Here's the Craigslist ad for when I bought the bike
And here's the before and after:
Thanks for looking!
- Part 1: Converting a '67 Honda CA160 to Electric!
- Part 2: Body Work
- Part 3: Battery Pack
- Part 4: Swing Arm Modifications
- Part 5: The Return of Project Dream-E
- Part 6: The Battery Enclosure
- Part 7: Wiring & Programming the Motor Controller
- Part 8: Final Assembly & Test Driving
- Part 9: Glamor shots, Parts List, & Build Cost