You might wonder why it's necessary to have two battery systems on the bike when a DC-DC Converter could be used to power the lights and horn. According to the EV Conversion Guidelines, a separate 12-volt system must be in place, distinct from the EV Traction Drive system batteries. This ensures that all safety systems, lights, and the horn will continue to function in the event that the EV Traction batteries fail or become depleted.

We are now in the final stages of installing the Motor Controls and connecting the Motor and Switchgear in our EV Conversion to bring the bike to life. By the end of this part of the build, we will have the motor running.

I believe the most challenging aspect of the build has been installing the batteries. If any part of this installation is not done properly and cautiously, it could lead to damage to the pack or, in the worst case, a fire. In this post I will be connecting the batteries, BMS, Testing and Securing the battery pack for the final time.

Since we are satisfied with the installation of the batteries, controls, and other cosmetic elements of the build, it's time to remove everything and start painting the structure before assembling all the components into the bike for the final time.

With the new Battery Box and Supporting Structure installed, we will review the installation and check the new Fairing Kit for fit.

The Engineering Design for the new Motor and Battery structure have been completed.