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Total:$2,645
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PartValueComments
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Kawasaki Ninja 250 (Purple)$300Includes title. Purchased after a kid dumped with the throttle open and allowed internal engine parts to become external. Complete but ICE partshttp://www.makeitlabs.com/photos/index.php?/category/2
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Mars ETEK brushless DC Motor$500The brushless ETEK is less common and better.http://www.evparts.com/products/street-vehicle/motors--dot/24-to-48-volt-street-vehicle-motors/mt5225.htm
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Sevcon MillipaK motor controller$500The best controller solutionhttp://www.electricmotordepot.com/products/Sevcon-Millipak-4Q-Controller.html
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Controller "Calibrator"$200Hand controller for tweaking controller parmshttp://www.thunderstruck-ev.com/sevcon-millipak-hand-held-calibrator.html
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Optima AGM batteries$800About 4 years old, kept charged, used lightly 1 season in EV bikehttp://www.hotrod.com/techarticles/general/hrdp_1009_how_to_charge_a_agm_battery/photo_03.html
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Vicor DC-DC 48-12 converter$50Convert 48v main power to 12V for normal bike use (lights, etc). Note: normal headlight will meet or exceed capacity so I planned to use HID or LED headlight
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Motor wiring harness$50
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Rear Sprocket$100Large custom sprocket in the back to get direct drive gear ratios correct.
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Front sprockets$20I bought a couple surplus motor sprockets - may need to machine a locking spline
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Chain$25Unused, should be long enough to work with new sprocket
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(4) 12 volt lead battery chargers$80To charge the batteries I wanted to charge each pack separately with a smart charger. I also wanted a solution that could fit under the tank.
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El Ninja book$20this was a good book to get ideas from but I didn't use much of his design. in particular I didn't like mounting the motor to the swing arm so it stuck out.
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Modifications/Created Parts
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Stiffen frameThe ICE normally forms part of the frame. I was worried about this with the smaller EV motor so I welded some struts to stiffen the weak point.
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Motor mounting platesMachined aluminum plates to mount the motor to the frame.
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Misc battery frame partscross parts are cut and the bolt tabs. ready to be welded.
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