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[Doctorbass]

Hi guys i finally found a way to boost the range of my zero with a relatively very cheap way !

Remember my past  8kWh Zero DS 2011 battery project ?.. i finally traded mt 2011 for a 2012 and abandonned the project so not it'S time to redo that project with the 2012 !!

Actually there is some tendense for EVers to get these Nissan Leaf / Chevy Volt /  Fisker karma battery from dammaged car parts store.

These battery are very profesionally made and can be dissassembled in modules.

The cost is about 250$  per kWh + shipping.  for the volt and Leaf.

The 2012 S zero battery is made in 18s groups  and the nissan leaf modules are 2s2p wich mean if i want to keep the modules as is i can use 9 modules to get 18s and 64Ah more

The 2012 S ZF9  is 120Ah so adding these mean i wil get 184Ah. that's a bit more than 12kWh guys !!

I can do 120km of combined city and highway so this will raise that range to close to 184km REAL !!

To install these i will  remove the charger under the battery and will place 4 of these modules to that location. This will lower the bottom of the motorcycle frame by about 2 inches wich is not bad. than i will place 2 others modules in the front of the battery behind the front wheel and the 3 last will be in the 2013 gas tank.

All these will be managed my the actual BMS of the ZF9 pack and the Leaf modules will be connected in parallel to the actual ZF9 cells brick including all balance connections bus. This will add 75 pounds to the motorcycle but the added weight will be spread in a way to keep center of gravity as is.

Here is the link to the spec of these modules  http://hybridautocenter.com/HAC4/index.php?option=com_content&view=article&id=72&Itemid=631

Doc



 

[BSDThw]

Nice!
Hope we see a new Doc project

How do you connect the sensing. The 4 Module says M4 nut for output terminal (only one for 2 in series?)

The mounting in the front of the battery will add 7cm + X. Last year I have done some thinking for the Meanwells to put it in the front of the battery.

I don't have real numbers left but I was surprised how much the wheel will travel backwards when deflecting - so take care!

[Doctorbass]

Yeah i agree i'll see for the space and front wheel travel.. that's a good point!

Even if i can not put two i'll put one only.. and 4 in the gas tank or 2 set of 2 one on each side of the actual battery.

Doc

[Justin Andrews]

Very interesting indeed.
I'd be interested to see you post more about this project as it comes along.

Another mounting option would be to mount (some of?) them towards the rear on a side luggage rack, might that balance the weight on the bike a bit?

[WindRider]

Nice idea Doc!

You could also set your bike up with Givi racks and make some Power Panniers by putting the additional battery packs in Givi e21 side cases.   

Looking forward to seeing this project.   

[Doctorbass]

Nice idea Doc!

You could also set your bike up with Givi racks and make some Power Panniers by putting the additional battery packs in Givi e21 side cases.   

Looking forward to seeing this project.

Yeah great idea with the Givi E21.. I'll have to get the square dimensions inside. The battery cells i'll have to install in each case will require :

290 x 210 x 130mm
11.4 x 8.25 x 5.12"

How much a complete kit for 2 sidecase and rack cost?
is it possible to quick remove the case?

I have some green army surplus metal case for bullet that match pretty well and are water tight but these are ZERO aerodynamic....


Doc

[Burton]

All Givi cases can be removed quickly, I have 3 on my bike right now; the e45's and v46.

If you have not put a lot of weight toward the rear before then you have some fun problems to figure out. Mainly a light front wheel causing wobbling or tank slappers depending on tread condition.

If you want to maintain handling it would be better to place the weight up front to the left and right of your forks.

[WindRider]

How much a complete kit for 2 sidecase and rack cost?
is it possible to quick remove the case?

I have some green army surplus metal case for bullet that match pretty well and are water tight but these are ZERO aerodynamic....


Doc

Talk to Harlan at Hollywood Electric for current pricing but I think it is around $550 for racks and cases.   They can be removed in seconds.   

External Dimensions: 16.5"L x 7.5"W x 13.5"D (420 x 196 x 348 mm) each
Capacity: 21 liters.
Max. load: 11 lbs/case

Load rating would be over specs.   

[BSDThw]

The Givi E21 are very "round" I had some trouble fixing my Chargers inside.

Stéphane I can make photos and metrics from my empty Givi if you need.

The Givi are ~120,-€ over here - my rack is self-built.

[Doctorbass]

The Givi E21 are very "round" I had some trouble fixing my Chargers inside.

Stéphane I can make photos and metrics from my empty Givi if you need.

The Givi are ~120,-€ over here - my rack is self-built.

Thanks for the offer. but before asking you dimensions, Do you think each case could handle about 35 pounds with some light modifications?

Doc

[BSDThw]

Good shoot - I wouldn't use it with 16Kg.

It has a sticker inside "Max Load 5Kg - Max 120 Km/h

[WindRider]

Lawyers come up with those weight ratings.

No matter where you put the weight you are going to exceed specs for something so you should just ask where the least offensive space would be and put it there.    I have seen riders fill the Givis with Beer and ice (pretty heavy I am sure) and they did not fall off.   I am sure it will negatively impact handling as well.   

[BSDThw]

My chargers are also heavier then 5kg.  The bottom part will hold the weight easily but the top key mechanism is a bit fragile.

I think Doc would do better to built one boxes - He has the capability to do!

[BrianTRice@gmail.com]

You can skip the E21's and get the largest, sturdiest cases that fit the Givi side racks: 48L and 37L Trekker aluminum models. I would recommend making a cheap cowling for these, though.

[rollandelliott]

So if you are going to use the Nissan leaf batteries, are you going to buy them new at $110 a piece
http://hybridautocenter.com/HAC4/index.php?option=com_hikashop&ctrl=product&task=show&cid=3&name=nissan-leaf-battery-module-model-2012-new&Itemid=605

or is there a cheaper way to buy them used from salvage cars?

Also what are you going to do with all the parts you never used for your ds2011 mod? I have a Zero DS2010 bike I want to upgrade the battery on. let me know if you want to sell them. thanks 704 7 to 6 97 ate ate is my phone number