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Our Journey: 1978 Honda cb400 EV Conversion

This is part 2 from this article

Quest Integration 3D Scan

We were fortunate to receive help from Quest Integration. They used a Creaform scanner and created a 3D model of our bike frame.

Solidworks Design

We got to designing the sub assemblies right away on Solidworks. We decided to use aluminum angle bar for the prototype. We purchased all the components and materials on a $5,500 budget and began CADing their dimensions into the design.

Three sub assemblies total: 48V, 12V and Motor Mount.

Complete 48V Sub Assembly

An closer example of our 48V assembly. Each of the assemblies had drawing packages associated with them which guided the manufacturing process.
The large awkward button is a kill switch. The port at the top is the charging connector for the J1772, the industry standard charger. (Donated by Avista)

The Custom 48V Battery

To power our drive train we made a custom lithium phosphate battery. Amp draw is 55 A with 48 V output. We are carefully storing and excited to see it's performance.

Current Progress of Prototype

Our team of four, with guidance from our advisor, have manufactured and installed the kit frame. Pictured here is out team and the most up to date assembly. The COVID outbreak stopped us short of installing the components and wiring.

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Written by Jack Burns

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