Electric Hurricane - 1987 CBR600 F1 Conversion

[furyphoto]

I am just getting started on my Honda Hurricane conversion.

Donor Bike is a 1987 CBR600 F1 - It's a moto Classic, and I am tickled pink that I was able to get a hold of it for $150 on Craigslist. It should make an awesome conversion.

Here is a shot of it seconds after I rolled it out of the bed of the truck.


And here it is an hour later, after some weight loss:


That was on Oct 28th 2012

Here it is on Nov 4th after being fully de-ICEd!




ABOUT THIS THREAD:

I wanted to keep all of the info on the project together, so I have reserved posts for explaining my major decisions, and decision making processes along the way. Hopefully this will help others watching understand the process of the whole build.

I will post a new topic for specific discussions, and then link to the topic, and put the conclusions and decisions in the appropriate post.

PLEASE JOIN THE CONVERSATION! I will need all the help I can get!

PHOTOS: I plan on taking lots of photos. I will post some in this thread, but there will be more in my ALBUM HERE. Take a look for extra views of the build.

TIMELINE: Unfortunately, I expect this to be a bit of a long term project, I have lots going on right now, and I will have to raise the money for the project in my spare time, so I will have to be cunning to get it done. I'll start with parting out the ICE, and other parts, which I hope will raise about $500. I'll let you know.

Cheers!

[furyphoto]

I have started a Motor & Controller topic to help with my selection:

http://www.elmoto.net/showthread.php...3448#post33448

Motor and Controller goals are:

Top Speed: 120km/h
Acceleration: Punchy but not drag strip stupid. I would like to be able to keep with a 400-500cc ICE off the line.
Target Curb Weight is < 350lbs
I weigh about 145 with my helmet and jacket on.

I would appreciate any help translating that into kwh/mile!

UPDATE: Decision made. I will start with an Alltrax 7245 controller and a Motenergy Mars ME 1003 motor. Based on other builders experiences, I plan to push both a bit up to an 80-88 volt system for a bit higher top end.

I acquired a used Controller from a fella on DIYelectriccar.com

I got a contactor from fellow elmoto-er RobO, A great guy to deal with!

I have bought the motor, and fuse, precharge resistor, and Diode form EVDrives.com in my neighboring WA state.

[furyphoto]

I have started a Battery Decision Thread Here:

http://www.elmoto.net/showthread.php...y-Battery-Pack!

I will update here with the results when decisions are made.

I am choosing Lithium batteries, right now the choice is between A123 20ah prismatic cells, RC lipo 14.4v 5Ah packs, and CALB CA 60, 70 or 100ah cells.

Visit the battery thread above for all the details.

UPDATE: DECISION MADE - July 2014

It's coming up on two years since I started the thread, but I did say that this was going to be a long term project. In those 2 years there have been some changes in batteries available for Elmoto conversions, the performance has gone up, and the price has come down. Hooray for procrastination!

For the bike I will be using Nissan Leaf Battery Modules, like this:


Each cell contains 4 3.7v 33ah Lithium Manganese battery cells in a 2s2p configuration for 7.4v and 66ah per module. I will be using 11 modules at first (44 cells, 22 in series) which will have average voltage of 84V, maximum 92.4V, minimum at 3.6V per cell - 79V.

The modules have nice terminals which will make connection for cells and battery monitoring very easy:


And Hybrid Auto Center is sending battery connection bars and covers along with the modules.


Here are some specs for the battery Modules and Cells

MODULE SPECIFICATIONS

Number of cells	4
Construction	2 in-series pairs in parallel
Length	11.9291" (303 mm)
Width	8.7795" (223 mm)
Thickness	1.3779" (35 mm)
Weight	8.3775 lbs (3.8 kgs)
Output terminal	M6 nut
Voltage sensing terminal	M4 nut
Module fixing hole diameter	0.3582" (9.1 mm)

CELL SPECIFICATIONS

Cell type	Laminate type
Cathode material	LiMn2O4 with LiNiO2
Anode material	Graphite
Rated capacity (0.3C)	33.1 Ah
Average voltage	3.8 V
Length	11.417" (290 mm)
Width	8.504" (216 mm)
Thickness	0.2795" (7.1mm)
Weight	1.7624 lbs (799 g)

and some charge and discharge curves samples from the reseller.





I am more excited than ever about getting the build under way now that my batteries are selected and will be on their way soon.

Cost for me for 11 modules including shipping right to the edge of the Canada/USA border was $1292.00 usd I will likely have to pay some Canadian tax when I head stateside to pick them up.

[furyphoto]

When I have info about my Charger and BMS decision making process, it will go here.

CHARGER UPDATE: I have decided on a ELCON PFC1500 charger. I found a used one in the right voltage range at a good price so that was a factor, but it was the charger I was leaning towards for a while.

It has an activate channel for turning charging on and off, and wide range input voltage 85v-260v, so I can easily charge from a regular 110v outlet, or a 220v level 2 EV charger. I will be including a J1772 charging port on the bike.



I am doing a modification I found online at DIYelectriccar.com to trim the final charger voltage to 90V, which is the max voltage I can use with my Alltrax AXE controller.

My BMS plan is going to be a custom monitoring system using an arduino. Still more to come on that.

[furyphoto]

When I have info about any Misc Parts and Accessories, it will go here.

[furyphoto]

RESERVED For finished project conclusions and Photos - (ambitious, aren't I?)

[furyphoto]

Time for the pre-fight weigh in...
I did the old bathroom scales trick, weigh one wheel with the scales, then the other, add them up!

Front Wheel = 78.4 lbs


Back Wheel = 87 lbs even


For a total of 165.4 lbs or 75.2 kg, not too bad a starting weight for bike for a small guy like me.
I also actually double checked the weight by stepping on the scales and picking up the naked bike. Apparently the bathroom scales can handle 307.4 lbs. I was a bit nervous, they are made out of glass. (-142 for me = 165.4)

A 60 AH lithium pack will be about 110 lbs or less, so I am hoping to keep the whole thing below 350 lbs curb weight. We will see.

[Spaceweasel]

Looks like a great start!

[Allen_okc]

welcome furyphoto to the forum, and space weasel what the H#@& is that avatar of yours, looks interesting!!!

[moon]

Welcome to the forum! Nice choice of chassis.

Also, I don't think I've ever seen anybody layout a thread like you have but its a good idea to keep the thread organized.

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