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[Doctorbass]

Awesome work.  I'd like to see more ventilation tho.  With holes at lowest and highest
points (assuming kickstand, there's a natural angle) you'd at least get some convection
flow. 

Anton's got some experience fitting 3 chargers into a tank area and the thermal
challenges that putting chargers in a closed space entails.

Terry and Liveforphysics bent a plate to hold the chargers under the bike, like you, but I
think they left the front and back open, so got more airflow that way. 

I think L started with insulation between chargers and battery but ended
up with a blower to send a low volume high velocity sheet of air through.
L has six SCv2 units though, he trimmed the motor vanes to make it fit : - )
And he has a battery pack he couldn't tell us much about until the 2018 models
came out. : - )

thanks togo,
Cooling will be better as i will install heatsink and blower on the sides of that pan... plus the added metal mass of the pan that will  slow down the temp increase ( 4 more pounds of aluminum).  Too much holes  in the pan would make easy water intrusion and high pressure during running the bike. I wanted to avoid that and keep charger protected from high sprayed water pressure and dirt. however i will also install internal blower to add air flow around the charger and cables.

I will post more update over the next days.

Doc

[togo]

Thank you, clearer now.

[Doctorbass]

I also forgot to specify that the orientation of the chargers in teh pan are different than the one from Terry and Luke.

Those choosed to install 4 chargers so they had to make a wider pan as you can see in the picture below, showing the charger pan from Terry (witch a a nice job btw)

In the pan design i choosed, the charger take  is 9.5" and 10.25" overall width dimension and include hiding/protecting  the cables inside wide while the  4 charger setup of Terry  take 10.6" wide and 11" wide overall and let cables exposed to teh sides.

As i know Terry charging setup is perfect for the use he is doing and he built it according to his requirement
I was inspired by him and decided to do similar but  to make a charger pan that many could use on their Zero and feel the units are safe and protected and require less care.

[togo]

Awesome!

Craig Vetter looks impressed.  Hope he's recovering well.

[BrianTRice@gmail.com]

I've been too busy to check the forums, but I'm glad to see this! I don't personally get excited about replacing the stock equipment, but this is really well designed and it's always great to have real drawings to reproduce the work.

Do I understand right that this actually preserves ground clearance? 3.437cm (1.353in) is less than the 1.73in depth on the Calex charger. If it's 3.437in, that'd be a significant loss of ground clearance... and I see that the charger depth is 66mm (2.6in) which indicates the latter. :/

Unfortunately, if I install a Power Tank, it'll displace my SCv1 and not the SCv2's. But $50 is worth spending if I can get those SCv2's installed permanently, and then put all my spare/adapter cables in the tank panniers I acquired for my SCv2's.

Maybe I'll put the Calex charger elsewhere as backup? I'll PM for clarification.

[Rugby4life]

I too am excited about this design. I'll be adding a powertank to my '17 SR as soon as they're off backorder so a charger in the tank area is not an option. If the pan is no wider than the frame, lean angle shouldn't be compromised too much.

[Doctorbass]

I too am excited about this design. I'll be adding a powertank to my '17 SR as soon as they're off backorder so a charger in the tank area is not an option. If the pan is no wider than the frame, lean angle shouldn't be compromised too much.

At the base the charge pan is 10.25" witch is narrower than the 12.25" of the bike frame

Also, at the lower area the pan is only 0.625"  lower than the original zero pan.. but the charger pan is same height on the entire lenght.. while the Zero pan is getting higher at the  end close to the motor.

Doc

[Doctorbass]

Now let's talk about heat dissipation:

The pan itself represent great dissipation surface.

On the outher pan surface it's 2.7 square foot  that radiate on the exterior! (and not counting the inside of the pan)

Each of the SCv2 units have strangely also 2.7 square foot of dissipation, however all fins are not open to the air, these are very narrow together so the heat exchange is not as efficient as a plain surface like the pan is. In that case i would derate that value by about 50%  so each Scv2 are about 1.35 square foot of effective dissipation area.

That would be correct to compare the entire pan as 2 of the SCv2 heatsink... but without blower.

The air convection around the pan should also help and be more important than the one on the SCv2 heatsink.

 In a couple weeks i will document all that and test that too.

Doc

[originalspacerob]

Those plates came out fantastic Doc.   Great job.  Looks like everything will fit pretty good. 

[togo]

Now let's talk about heat dissipation:

The pan itself represent great dissipation surface.

On the outher pan surface it's 2.7 square foot  that radiate on the exterior! (and not counting the inside of the pan)

Each of the SCv2 units have strangely also 2.7 square foot of dissipation, however all fins are not open to the air, these are very narrow together so the heat exchange is not as efficient as a plain surface like the pan is. In that case i would derate that value by about 50%  so each Scv2 are about 1.35 square foot of effective dissipation area.

That would be correct to compare the entire pan as 2 of the SCv2 heatsink... but without blower.

The air convection around the pan should also help and be more important than the one on the SCv2 heatsink.

 In a couple weeks i will document all that and test that too.

Doc

Awesome stuff, doc.  I love your stuff and your analytic way of approaching it.  Assertion is nothing without experimentation and analysis.  I assume the material will be thick enough to transfer the heat well?  (I only ask because experiments transferring heat to the frame to use the frame as a radiative device have not faired well.)

[Doctorbass]

Yes it will be thick enough.

In total there is about 7 sq inch cross sectional area of aluminum that will transfer heat between the SCv2 to the sides   ( 3/16" x 18" x 2)

Doc

[BrianTRice@gmail.com]

Repeating an offhand FB comment I made, I'd like to outline a follow-up idea for "side-pans" to achieve that "BMW Boxer" idea thrown around for a while.

A similarly-fabricated aluminum box that mated to the side of the frame and supported 2 SCv2 units on each side would also be quite interesting.

The naive approach to mount against the existing 2014+ frame attachment points seems worth bypassing in favor of a way to have the flange-edge brace itself against the inside of the frame square tubing. And then some tiny brackets could still use those existing threaded holes to secure them further, but primarily loading via a large surface area seems worth pursuing.

I'll try to make drawings or a cardboard mockup if/when I get the time.

[BrianTRice@gmail.com]

Yes it will be thick enough.

In total there is about 7 sq inch cross sectional area of aluminum that will transfer heat between the SCv2 to the sides   ( 3/16" x 18" x 2)

Thanks so much for working this out, and especially for setting a nice example of how to put together a project for a Zero with some fit and finish and engineering drawings.

[Rugby4life]

What's up Doc? Have you installed and tested your design yet? I'm very interested in applying your solution to my bike if yours turns out well.

[Doctorbass]

What's up Doc? Have you installed and tested your design yet? I'm very interested in applying your solution to my bike if yours turns out well.

Hi

It will turn out well 

i'm in the final process of design of the rev 1.0. that,s alot of details to make it sinple to keep cost low and to make it to fit and match  the most perfectly the actual Zero body.

you can also follow the FB  zero owner group page for more info

Doc