Drivetrain is in and has been run on a spare pack. The custom tank pack still needs to be spot-welded; remaining work is small aesthetic finishing touches.
Done
Pack layout: 200 cells designed to fit the original tank, from 340 re-wrapped used 18650s.
Custom kWeld spot welder after a portable welder failed on nickel strip.
QS120 9 kW / 72 V motor, controller, and DC-DC on steel + PETG mounts that reuse the original engine bracket.
Two-stage chain reduction with FreeCAD shims, spacer, and cut-alignment fixtures for the mid and rear sprockets.
LED conversion for headlight, signals, running, and brake.
First motor test: rear wheel driven from a spare pack, not the custom tank pack.
Open
Spot-welding the custom 200-cell tank pack is more than halfway done. Remaining work is finishing the pack and small aesthetic finishing touches.
Motor
QS120, 9 kW / 72 V
Pack target
200 × 18650 in the original tank
Chain
428, two-stage reduction
Rewrapped 18650s for the custom moped packCell layout for the custom moped packHow the cells will be connected — nickel-strip planHow the cells will be connected — series groupsSpot-welded module for the custom moped pack — this work is more than halfway doneSpot-welding the custom moped packSpot-welding the custom moped packTwo-stage chain reduction installed, indoorsFull side during the reduction installMid sprocket, both chains, and rear wheelMid sprocket and chain from aboveInstalling the reduction; motor in the original engine spaceMotor installed; jackshaft and 428 chain on the floorRear wheel, shock, and motor outdoorsRear of the bike on a wood block, chain cover offChecking sprocket alignment on the rear hubJTR rear sprocketJTR 269 / 428-chain sprocket drawingMid sprocket on the jackshaftJackshaft with mid sprocket and clutch platesOriginal clutch basket / sprocket carrierOriginal clutch cover with needle-bearing grease instructionsCut fixture clamped to the jackshaftCut fixture set up; cut sprocket on the groundRear hub, original sprocket, and pedalRear shock, footpeg, and swingarmRear wheel and sprocket through the rimFirst motor test — driving the rear wheel from a spare pack, not the custom tank pack
