Removing the Frame and Battery Structure for painting the assembly in preparation to finalise the complete installation.

evconversionrider
Mar 16
3 min read

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.

I will begin by taking out the controls and batteries from the structure, which will allow me to remove the structure and prepare it for painting.

I will exercise extra caution when removing the batteries since they are charged, and everything around the bike is metal with exposed battery terminals.

First, I will take out all the wiring and controls from the top of the battery box and set them aside to ensure we don't misplace any of the cables we've assembled.

I will now carefully take out the batteries to prevent them from shorting against the aluminum box and place them securely to avoid falling or shorting against one another.

The next step involves removing the Main Charger and Bike Chain to detach the remaining component connecting the structure to the bike's frame.

With everything taken out of the Box Structure, I can now take out the 3 retaining bolts and lower the assembly from the bike's frame.

Before I can prepare the structure for painting, I need to mark, drill, and tap the holes for mounting the DC to DC Converter and the Inertia Switch.

With the brackets and fixing holes finished on the Box and Frame Support, I am applying a durable rust and corrosion-resistant paint to the frame and box to ensure the new structure is protected for years of service.

After the paint has dried and hardened, I can start assembling the bike for the last time. During this process, I will ensure that all the structures and components are properly fitted, bolts are tightened to the correct tension, and everything is installed according to the standards needed for the bike to be certified and registered for road use.

The initial step involves reinstalling the Electric Motor into the frame. Prior to doing this, it is necessary to confirm that the motor cables are orange in colour to adhere to Vehicle Standards Bulletin 14, the National Code of Practice for Light Vehicle Construction and Modification.

There is multiple section within the standards associated with the electrical and mechanical parts of this build. The National Guidelines For The Installation Of Electric Drives In Motor Vehicles, states in the Scope of the document that the guidelines do not apply to ADR category L-group vehicles and motor cycles.

Since there is presently no document specific for Motor Cycles, I will adhere to the guideline, ensuring that the electrical installation for the drive system, wiring diagrams, and safety circuits align with the code, just as we did with the structural engineering of the battery structure.

As the cables on the motor are not orange, I was able to source some orange expandable sleeve that I can slide over any cables that are part of the HVDC circuit within the drive and charging systems on the bike.

While installing the motor and reassembling the structure to fit back into the bike's frame, I will attach the orange sleeve and apply heat shrink to the ends to prevent the sleeve from fraying.

With the assembly now finished, we can reinstall it into the bike frame and tighten the bolts that secure the assembly to the frame, preventing any movement, flexing, or twisting during use.