eVFRNo ICEMeLonimotorReady for stage 2prototypeBefore maiden voyageSynkromotive
OwnerTravis Gintz
LocationLake Oswego, Oregon US map
Web/EmailWebPage email image
Vehicle1986 Honda VFR700F
Bought for $400 from a guy in Florida, shipped to Oregon. Parted out most of the original ICE.
MotorAdvanced DC K99-4007 Series Wound DC
K99-4007 Its electrically equivalent to the ADC K91-4003, but has a different shaft. Just cutting off the end.
DrivetrainChain driven direct drive, currently have a 44 rear sprocket (stock) 530 chain and just got 11,12 and 13 tooth front sprockets, Configurable for 4:1 down to 3.4:1 ratio. [update] 3.38 is too low, and we'll try 11 tooth (4:1) Might need to upgrade rear sprocket.
ControllerCrux Electronic Synkromotive (Crux) 600A 156V DC controller
Synkromotive DC controller. Currently in final stages of development. Tested at 600A at 156V on a Myers NMG. Very flexible, can run different motor types (PM and Series). Displays stats and settings on PDA.
Batteries12 Power Patrol SLA1116, 12.00 Volt, Lead-Acid, Gel
12 of these weigh around 160lbs. I'm going to have one 144V pack. Lithium plans for later. [update] testing with 72V right now (2 packs in parallel)
System Voltage144 Volts
Charger Synkromotive
Custom designed 1500W 120/240VAC input, 144V output balancing battery charger. Very flexible and modular. Prototype being built.
Heaternone
DC/DC Converter Synkromotive
Part of the charger system above, also modular.
InstrumentationCurrently working is a custom written Visual Basic 2005 app written for a pocket PC, running as a Dash. Integrated with the controller. Will be integrated with the battery management/monitoring system. [update] a custom LCD display is in development
Top SpeedTarget of 60mph.
Accelerationslow with the 3.4:1 ratio. Changing sprockets to get better acceleration. Top speed should not be effected too much, as I'm using 144V to the controller.
Range10 Miles (16 Kilometers)
Looking to get 10-15 miles per charge. Work is putting in a charge receptacle for me sometime this next year. Its only a 7 mile commute to work, all 35 miles per hour or below.
Watt Hours/MileHopefully this is low, its full fairing, fairly low rolling resistance, and all aluminum frame.
EV Miles
Start:4,270 Miles (6,870 Kilometers)
Current:4,270 Miles (6,870 Kilometers)
Total:0 Miles (0 Kilometers)
 
    As of 6/23/2008
Seating Capacity2 adults, but its just for one person commuting.
Curb Weight0
Bike weighs about 150 totally stripped naked before conversion. Electric Motor is 56lbs, batteries are 160lbs. It will be lighter than the original by 50-75lbs. Stock is ~485 or so.
TiresBrand new
Conversion Timefirst bike I had about 10 hours into it. The second bike (this one) has about 40 into it so far after removing engine, cleaning it up, and fabricating a motor mount.
Conversion Cost1986 VFR: $400 + $675 shipping - 1075 (sold engine and other ICE stuff) = $0
Batteries: $50 in gas to get 33 batteries as well as another frame and a 1.25 HP GE Perm Magnet motor.
Dell Axim PDA: $75 with serial docking station
Relays and terminals: ~50 from a surplus electronics place.
Sprockets, chain, chain break: ~60 shipped
Battery Charger proto parts: $285 shipped
battery/motor cable terminals: ~$30
Cable: ~$40


Additional FeaturesLooking to get this rolling in the next month or two to be able to test and program. Fully functional by spring. Interfacing the controller to the pocket PC so I can monitor the current/voltage levels throughout a trip with acceleration, speed, time-stamp, etc to log and graph for later use (long term goal). [update] currently running at 72V.
6-20-08: Its been a fun week!Posted 6 new videos.
WebPage

6-17-08: So, she's actually running now.

Accel is slow, because I chose a 13 tooth front, stock rear... to start. I'll be changing to 11tooth tonight to see how it helps. We might go larger sprocket to help even more. It JUST got running, and there's lots of work to be done (and it looks like Frankenstein without the fairings).

WebPage


5-23-08: Finished the battery tray/pack. Just need to put some finishing touches on it and move the lower tray further back (kinda hits the fairing). Its not important right now, just details. Going to start wiring up the pack next week. 400A controller is waiting for me at Synkromotive. Using a relay charger for now that we use to balance the pack, quick and easy. Going to use the magura for now, but going back to stock hardware with a fabricated design later.
WebPage

5-16-08: More pics of the beefed up motor mount as well as the mocked up battery trays. We can fit all 12 batteries in, very low to the ground and still fit the fairings on the bike.
WebPage


5-9-08: Beefed up the motor mount a little bit, cleaned up the mount and started planning ideas for the battery cages/boxes. Helped with some connector/ layout/ functionality ideas for the charging system. Prototype boards should go out this week or early next week. Once we get them, we'll populate the boards, install and test with the 12 SLA's that I've got.

5-3-08: Finished the motor mount, attached the sprocket and chain and tested out the motor with a 12V 18Ah battery. FINALLY got the tire spinning under power from the series wound DC motor!!! Also got both bikes titled in my name.

WebPage for a video and some pictures.



4-2-08: Got together with another EV'r (and VFR owner) that I met and worked out the motor mount design. Going to start cutting/welding this week. Fabricating everything out of aluminum. Got an idea of battery orientation. It was tricky fitting 12 18Ah batteries in, but they fit easier than larger SLA's due to their size. Also, going to put a standard motorcycle battery in the stock location for auxiliary to act as a buffer for when the lights go on. 6A DC-DC converter will be connected to the aux. Preliminary Design for battery balancing is finished, time to implement. Designing the BMS control aspect is next step. Bike is going to be 144V system with current limiting/voltage limiting in the controller.

3-20-08: Bought parts for the charger prototype. Received sprockets, chain and break from Surpluscenter.com. Got ring terminals for 4Ga battery cable and 2Ga motor/controller cable. Getting some cable from work that is super flexible. Mocked up some motor mounts with cardboard, fabrication begins soon.

3-2-08: Swapped the frame and ready to get some motor mounts fabricated. Currently trying to figure out what gear ratio to go with. I might use stock for now, with chain from SurplusCenter as well as a sprocket from them. I can always change it around later, but buying a new rear sprocket might be more expensive. Got a GE 48V 300A controller and will be testing the mechanical. Also got a contactor.

1-22-08: Updated the website. Got the blog set up correctly and redirect works now. The gallery shows on the blog now. Synkromotive moved. Got the new frame and title. Working on the battery balancing with Synkromotive. Controller is close to the next revision. Still need to figure out charging for the batteries.

12-20-2007: Updated my Blog. Working on integrating Coppermine and Wordpress. Not too great with web programming, so It'l be slow.

Linked to pictures of the PDA program on my blog. Tested the second motor and it works fine. Paid for my frame, awaiting its arrival. Going to start the swap now, so I can use the non-titled frame for fabricating a motor mount/battery cage. Easier to do off the bike. Also bought a rear shock for the first VFR so we can get 2 going at around the same time (minus batteries).

Found info on Oregon's tax credit for EV's. They said there's no reason that I shouldn't be able to apply for it, I just need receipts for everything. Up to $750 for a homebuilt.

12-7-2007: Ordered a K99-4007 motor from Surplus Center Its electrically is the same thing as a k91-4003 motor, with a difference being: A) Lack of side mounting plate and B) the shaft is different.

I called Jim Husted and he said to get 2, and press new shafts into them to make them equivalent to the K91.

Datasheet available upon request, just email me.

12-1-07: Got the Pocket PC program working with the controller. It displays some of the debugging and fault information we need, as well as the current, voltage etc. MAJOR milestone for my project. Just need to get a decent looking dash running with some decent contrast for use outside. the PDA I'm using is very viewable. The com port is isolated, so its not going to fry my PDA.

Got a charger board from Synkromotive and am populating with components this week. Should have a working balancing charger soon. Also bought 18 30A relays for the charge system. Going to try and put everything in a box. I'd like to use my smart charger I bought, but it faults when I disconnect and go to another battery. Might call the manufacturer and see if there are some options.

Made a mockup of the motor Jim Husted is rebuilding for me. The cardboard model is 7" and 13" long and comparable in size. It fits inside the chassis no problem. His motor has a mounting plate on it for side mount. Also, I've got 28" from the gas tank to the bottom of the fairing, so I might be able to fit all 12 batteries vertically this way. There's plenty of room. I might borrow a welder and tack weld a frame together.


11-26-07: Bike has no original ICE parts on it. Installed a Magura Twist Grip throttle. Put panels back on. Going to start sizing different motors on the frame (cardboard mock-ups). Buying a frame to replace the lost title frame and will use that to create 2 sets of battery cages and motor mounts. Going to get the gas tank into Jim to cut with a torch. Should be ordering motor fairly soon. Looking at Advanced DC motors above 72V. Since I'm using 144V at 18Ah (80A continuous, 200A max for 5 seconds) its high voltage, low current... but a fair amount of available kWh.

code by jerry