Electric Ninja 250 Cafe

Without the motor in, the frame is weak....you need to put something to replace the stressed part of the motor....otherwise the bike will fold in half.
 
Mydlyfkryzis said:
Without the motor in, the frame is weak....you need to put something to replace the stressed part of the motor....otherwise the bike will fold in half.
Click to expand...

When I disassemble the roller and do the frame mods, I'm going to add a gusset at the weak point.
 
Just some updates. Trimmed the bottom of the tank flat, gives it a bit more of a vintage look and let's me tuck the batteries up a touch higher. Excuse the blurry pictures, I shake too much.

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Also made up a tray for the chargers/relays/whatever else I can fit. It bolts to frame and will have a u-bolt securing the top. Made from 1/8" 5051 aluminum, the tab was bend with a pair of those duck billed vice grips.

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Motor fits nicely. Excuse the flash, but atleast it isn't as blurry, right?

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Now that the motor mounts are finalized I sent them to the water jet. They'll be done by mid next week. This weekend we're doing all the frame mods. And here's where it's at currently (and yes, I'm making a sprocket cover).

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Very cool project. :-)

What controller are you using?

What are you aiming at for front and rear sprocket sizes? (Acc vs top end)

What is your anticipated power output in Hp/kW?

The battery packs and motor once fitted will make the entire module plenty strong as you know, the motor mounting area looks good - I'm interested to see the fixture on the top of the battery pack to the frame under the "tank". That imo is potentially the weakest area you have currently - but It's purely because you haven't posted any close ups of that area yet? You mentioned a gusset? If it were me, I'd have a solid fixture area all the way along the top, moving as close to the seat area as possible, locking the battery and motor module as tightly as possible (ie 3 mounting areas as opposed to 2).

Flash pics are just fine :-D keep us updated. Enjoying your project.
 
Mydlyfkryzis said:
Without the motor in, the frame is weak....you need to put something to replace the stressed part of the motor....otherwise the bike will fold in half.
Click to expand...

I wouldnt ignore this! Your going to need to brace it so its structurally all ties together, thats what the engine does. Great project though, I was looking at doing an electric build but the mileage from a charge wouldnt have been enough to get to to work let alone back again. You have a good base though, quite a light frame.
 
Dale said:
Very cool project. :-)

What controller are you using?

What are you aiming at for front and rear sprocket sizes? (Acc vs top end)

What is your anticipated power output in Hp/kW?

The battery packs and motor once fitted will make the entire module plenty strong as you know, the motor mounting area looks good - I'm interested to see the fixture on the top of the battery pack to the frame under the "tank". That imo is potentially the weakest area you have currently - but It's purely because you haven't posted any close ups of that area yet? You mentioned a gusset? If it were me, I'd have a solid fixture area all the way along the top, moving as close to the seat area as possible, locking the battery and motor module as tightly as possible (ie 3 mounting areas as opposed to 2).

Flash pics are just fine :-D keep us updated. Enjoying your project.
Click to expand...

Great questions here, I'll take them one at a time:

- What controller are you using?

I'm using an Alltrax SPM72400 rated at 72v (up to 90v) at 400A. Made in USA, and fully programmable by the user with a USB cable.

- What are you aiming at for front and rear sprocket sizes? (Acc vs top end)

I bought 11-15 tooth front sprockets from surplus center, and will get a custom rear sprocket made when I have a better feel for how the gear ratios affect performance.

- What is your anticipated power output in Hp/kW?

My motor is capable of 23KW at 400 A for one full minute. So around 31 HP.

- The battery packs and motor once fitted will make the entire module plenty strong as you know, the motor mounting area looks good - I'm interested to see the fixture on the top of the battery pack to the frame under the "tank". That imo is potentially the weakest area you have currently - but It's purely because you haven't posted any close ups of that area yet? You mentioned a gusset? If it were me, I'd have a solid fixture area all the way along the top, moving as close to the seat area as possible, locking the battery and motor module as tightly as possible (ie 3 mounting areas as opposed to 2).

I'm going to use steel angle that bolts to those high strength welded posts. I designed the mounting system to be both flexible and expandable. I'll also be welding gussets at the main bend point of the frame, similar to this image.

gussets.jpg
 
FerousBastard said:
Definitely onboard with this. The sound of an electric bike revving is rad like nothing else.
Is that an Etek motor?
Click to expand...

Not an Etek, but based on the same design. Has double the brushes though, so it can handle higher amps and generate a lot more power.
 
Frame mods:

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Modified the stock seat pan to follow the new rear end. I'm going to keep the passenger pegs.

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Just need to find the right tail light
 
Nice job on the seat and frame mod, after welding and painting it should be hard to tell it wasn't originally like that.
 
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