Rebuild BM2 green...

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Re: Rebuild BM2 green...

Postby terry2 » 28 Dec 2015, 16:20

Looking great so far. I bet you'd love to attach your jet engine to it :D
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Re: Rebuild BM2 green...

Postby Burgerman » 28 Dec 2015, 17:01

Well not really. Its a bit loud and catches fire.
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Re: Rebuild BM2 green...

Postby ex-Gooserider » 29 Dec 2015, 07:22

Burgerman wrote:Well not really. Its a bit loud and catches fire.


But isn't that why they make earplugs and Nomex underwear?

Wouldn't be great for range, but might be fun to get back on the drag strip.... :mrgreen:

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Re: Rebuild BM2 green...

Postby terry2 » 29 Dec 2015, 10:04

ex-Gooserider wrote:
Burgerman wrote:Well not really. Its a bit loud and catches fire.


But isn't that why they make earplugs and Nomex underwear?

Wouldn't be great for range, but might be fun to get back on the drag strip.... :mrgreen:

ex-Gooserider



Agree :D
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Re: Rebuild BM2 green...

Postby Burgerman » 29 Dec 2015, 11:05

Image

Image

Image

Image
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Re: Rebuild BM2 green...

Postby Burgerman » 29 Dec 2015, 21:53

Casters and forks fitted...

Slowly but carefully.
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Re: Rebuild BM2 green...

Postby Burgerman » 29 Dec 2015, 21:57

Another
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Re: Rebuild BM2 green...

Postby Burgerman » 29 Dec 2015, 22:00

And another
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Re: Rebuild BM2 green...

Postby HiltonP » 30 Dec 2015, 11:46

Shit but it's looking good John!
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Re: Rebuild BM2 green...

Postby hank » 30 Dec 2015, 12:30

:mrgreen: :mrgreen: :mrgreen: 8-) Getting there.
f55s bm1 clone.
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Re: Rebuild BM2 green...

Postby Burgerman » 30 Dec 2015, 15:54

Adjust and align...

810_1104.JPG
Pic 1
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Re: Rebuild BM2 green...

Postby Burgerman » 30 Dec 2015, 15:56

Again... Line up motors, adjusting all roast joints ((c) jenny) (2nd from left, top, too long, etc)

810_1107.JPG

pic 2
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Re: Rebuild BM2 green...

Postby Burgerman » 30 Dec 2015, 16:01

Rear battery door, hinges, etc, and replace top motor mounting bolts with thinner head ones to miss battery terminals by greater margin.

810_1116.JPG


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Re: Rebuild BM2 green...

Postby Burgerman » 30 Dec 2015, 16:02

From the rear, flash never fired so colours a bit wrong...

810_1114.JPG
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Re: Rebuild BM2 green...

Postby Burgerman » 30 Dec 2015, 16:03

Rear quarter - distorted because I am about 12 inches away...

810_1117.JPG
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Re: Rebuild BM2 green...

Postby Burgerman » 30 Dec 2015, 16:06

inside...

810_1120.JPG
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Re: Rebuild BM2 green...

Postby hank » 30 Dec 2015, 17:29

Burgerman wrote:From the rear, flash never fired so colours a bit wrong...

810_1114.JPG


Like this shot. 8-)
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Re: Rebuild BM2 green...

Postby Burgerman » 30 Dec 2015, 19:30

You can see the stainless steel door hinges used on the battery door! :lol:

For anyone skinny, building a narrow chair, you could still move the rear wheels 10mm inboard (each side) if required and then it will be under 25 inches total. I left the 10mm gap so I can later on bolt on 4.5 wide rims, and even lower profile 145 tyres. As soon as I can find a set this side of the Atlantic.
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Re: Rebuild BM2 green...

Postby Burgerman » 31 Dec 2015, 15:06

Seat plate/frame. Too much dump here, shortened, footplate mounts cut off, different mountings, and powder coated.

810_1128.JPG
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Re: Rebuild BM2 green...

Postby Burgerman » 31 Dec 2015, 16:36

Which I needed on, because it lets me configure the battery in multiples of 8 to take the best advantage of the space available. This is ESSENTIAL to take full advantage of the lithium battery.

Max capacity I can fit (easily) is 120Ah. (80x 12cells). Because one of the great things about these headway cells, over the typical prismatic cells, (or lead) is that it can be configured to use up all of the available space. It need not be rectangular. Or even all in one place.

See below:

810_1131.JPG


810_1132.JPG
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Re: Rebuild BM2 green...

Postby Burgerman » 01 Jan 2016, 01:31

My cells have been sat in a box for 6 weeks awaiting recharge.

They were charged individually to 100%, 1000mAh accurately removed (taken out), then stored 1.5 month. 5A charge 25mA termination, @ 3.600CV.

Subsequent re-charge at 5A and 200mA termination current, @ 3.600V Gives me figures like this (this is 8 cells from 80 that I have.)

Code: Select all
Cell  Beep@CVpoint  EndCharge@200mA  Self Discharge mAh (Lost)
1     809      1038             38
2     789      1016             16
3     775      1002             2
4     756      997             -3
5     783      1024             24
6     896      1122             122
7     782      1019             19
8     788      1020             20 


As you can see they all vary, and cell 6 varies more than I like. I ordered 2 extra cells. I may not use the 122mAh lost cell. This way I can assemble GROUP[S of cells that have the same AVERAGE self discharge. So they will stay in balance if unused for a while.
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Re: Rebuild BM2 green...

Postby Burgerman » 01 Jan 2016, 20:26

810_1134.JPG


The long boring process of building a 120Ah battery. Every cell group tested for same self discharge rates, careful planning so we get each cell the correct way around...

One at a time.
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Re: Rebuild BM2 green...

Postby Burgerman » 01 Jan 2016, 20:47

This cell required the 1Ah removed, plus 16 extra mAh to be fully charged. So it had just 16mAh self discharge.

Image1.gif
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Re: Rebuild BM2 green...

Postby Burgerman » 01 Jan 2016, 21:26

The BLACK end is negative obviously. The other end is positive and silver. And vented. Dont use too long bolt here.

810_1136.jpg
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Re: Rebuild BM2 green...

Postby Burgerman » 03 Jan 2016, 01:25

Code: Select all
PL8 charger used.
Charged individually to 100% 15mA termination 3.600v, then 1000mAh

accurately removed, stored 1.5 month in box a cupoboard.

Then, 5A charge 200mA termination, 3.600CV.
Subsequent re-charge gives us the amount lost through self discharge:

Cell  Beep@CV  EndCharge@200mA  Self Discharge mAh (Lost)
1     809      1038             38
2     789      1016             16
3     775      1002             2
4     756      997             -3
5     783      1024             24
6     896      1122             122
7     782      1019             19
8     788      1020             20   
9     690      990             -10
10    712      1104             4

11    725      995             -5
12    756      1011             11
13    813      1019             19
14    781      1016             16
15    815      1020             20
16    813      1023             23
17    819      1034             34         
18    768      1008             8
19    777      1013             13
20    902      1120             120

21    761      1010             10
22    780      1012             12
23    802      1047             47
24    796      1015             15
25    760      1007             7
26    760      1018             18
27      0      44      44? Over full in seconds?  This one wasn't discharged 1Ah...
28    800      1016             16
29    800      1016             16
30    748      1018             18


More done! 30, only 50 to go!

810_1138.JPG
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Re: Rebuild BM2 green...

Postby terry2 » 03 Jan 2016, 20:31

Looking great BM(I'm jealous as hell)
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Re: Rebuild BM2 green...

Postby Burgerman » 04 Jan 2016, 04:58

Well its hard work. Esp if you spend most of the time held up waiting for a carer to pick up that screw, tool, bracket, or whatever that you needed and you have been running over all day, or waiting for the post from china for some obscure tiny thing you cant do without...

I have a BM3 with a failed Cush drive rubber I need to fix, so cant use it. But cant fix it because I have a BM2L (lithium) in the way covering every spare bit of space in 200 bits and pieces.

But don't watch. Get the hammer out!
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Re: Rebuild BM2 green...

Postby Burgerman » 04 Jan 2016, 05:04

Anyway, my mates are so used to me turning up with new chairs they no longer go wooo! They don't notice.

That's why I did polished alloys, fat low profile tyres, Kawasaki green ultra bright welding mask paint, orange/blue battery etc. This one was meant to stand out. Might fit a bright coloured car race seat yet!

I am normally of the opinion that chairs should be neat, clean, and go unnoticed. So black and dull and invisible.
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Re: Rebuild BM2 green...

Postby Burgerman » 08 Jan 2016, 22:18

Here's one I made earlier. 80 12Ah cells, split into 2 packs, for easy lifting of uneven size and obscure shape to allow some parts to be 7 cells deep while others are 5...

120Ah and still 50lb lighter than a couple of lead bricks.

Looks odd. Fits great. Will allow HUGE range and uses up space wasted under the seat to the millimetre.

810_1173.JPG
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Re: Rebuild BM2 green...

Postby motoman » 09 Jan 2016, 22:35

Burgerman wrote:[img]

Image


This pic is actually after a mid air collision with a Cessna I believe :) Nomex undies and ear plugs would have been ineffective :(
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