The "Juice Cafe" Racer. From start to Ton up! ( The Build Begins)

If you ever wondered ( I did) what all the parts for one of our builds looks like
before we start the assembly process…there it is!

More later!


For another touch of Green, we have moved the bike to the “Solar shed” so we can do the build off the grid.

60 days and counting…


Today’s Work.

Mount motor, chain, rear and front sprockets. Locate contactor and Controller mount.
Attempt to replace ugly front master brake only to find new brake line bolt needs fine threads, not course threads, of which I have a box of.
Will pick up the correct one tomorrow.

59 days and counting.

3/1/11 Tonight:
Final assembly for the racing brakes.

I had an old left hand master brake and ran it to the back
brake since I do not like running a foot brake.
This saves me several pounds in weight and also lets me
put the foot pegs anywhere I need to for comfort.
It works equally well if you have a drum brake as you can
use the old clutch handle. It does not take long at all to
master it as it is the rear brake.

I added a new racing brake to the right side.
This unit takes a special fine thread "flow bolt’ .
$8 later and we are in business.

58 days and counting!

The standard street brake and the much lighter racing brake.

Got Controller and Contactor mounted. Started measuring for fiberglass placement.
Started marking tabs for trimming.

57 Days and counting.

Tonight we “flipped” the clip on handlebars so we had better
clearance in not hitting the tank during hard turns.
We mounted the hand grips, trimmed off over a pound
of excess metal and tabs. I sat on the bike to see if everything
so far felt good…it felt great! We also trimmed the rear tire
splash guard only to find out we needed to add something else so
the motor does not get rocks in it, but still gets good cooling air.

56 Days and counting.

3/4/2011 Update: Time to start the wiring.

We started to do the “first run” of the
wiring. This means I use leftover sections of cable to get it
running before making the correct size and length cables.
This makes it easier to fix an issue before making up new
cut to the exact length power cables. The smaller wires
(lights, throttle, etc.) are all run with new material.

We cut off about a pound of tabs and excess material.
Also a final alignment of the rear wheel in relation
to the motor was completed. Looks straight to me!

The shock is new in design and function, but looks old school.

55 days and counting!

3/5/2011 Update : It runs!

It …is…Alive…ALIVE!!! (Well the tire spins anyway.)

After a run to Lowe’s (yes Lowe’s) for a few connectors and wire,
The motorcycle runs, and runs well. I am so tempted to take it down
the street, but I will wait until it is truly street legal.

Other work today: Mounted the relays for the headlight, GPS and
Horn. We attached the GPS/Speedometer and set up the system
battery. The rest of the day was spent ordering the last few things
we did not know we needed until we started to get things together.
That is normal as each motorcycle is a unique build.

54 days and counting!

3/6/2011 Update: Wires, Wires, Wires.

Today we wired up a charging port extension. The center battery
box is covered by the top two boxes so the charger port is
not accessible. I wanted to run remote ports anyway since it
makes it easier to charge everything up with all the ports
aligned up. This center box had to be done first so
that I could get it secured into the battery rack. The other
3 boxes can be reached much easier with the fairing off.

We also changed the rest of the motor and structural
bolts to a grade 8 for that little bit of extra insurance.

53 days and counting!

3/7/11 update: Fuses!

When it comes to an electric vehicle, a fuse can save your
life! If nothing else, it may save all of your hard work!

A fuse block was added (we have a fuse on the controller too!)
and the final wiring has begun. Now when I turn on the key power
“ICE ignition” switch, the controller and GPS/Speedometer
activate. I have one more all in one switch coming in the mail.
The headlight switch and horn run the …headlight and horn.

The blinker switch is used as the emergency cut off. Blinkers
are not required here and I found drivers pay more attention to a
rider pointing to the direction they want to go than a blinker.

52 days and counting!

3/8/11 update: More Wires?

The handlebar switch came in so everything has been wired up with
the exception of the headlight, taillight and horn. The handlebar switch
powers their associated relays which were wired up and tested today.

Since everything goes through separate relays, there should not be
any electrical strain on the key switch, which was also mounted today.
All it provides is relay coil power.

The aluminum key switch mount will be sanded and painted when
we tear down the bike for final cosmetic painting and cable trimming.

First fit, then finish. : )

52 days and… still counting!

3/9/11 update: The Headway auxiliary battery!

Today we took a 13 pound, 12V 20AH Lead SLA battery
that runs all of the 12 volt system and replaced it with
a 6.5 pound, 12V 20AH Headway battery. Since we had
a few extra Headways lying around, it was time to put them
to good use. We have a 55w headlight, a few LED lights,
a GPS and a few relays so 20 AH will be more than enough
for a day’s ride on the Electric racer. It will be charged
with the same individual chargers used on the rest of the
bike so that every pair of batteries will be fully balanced.

Tomorrow, it will be installed and tested……fun stuff!

51 days and counting!

3/10/11 Update. Protecting those Headways!

I can monitor the main pack with a meter as I am riding
and I know my range, but what about after I am done
riding for the day? What if I am in a hurry and leave
the key in? The main pack can survive for days since
the controller uses very little when the bike is just
sitting there and there is no DC to DC converter to kill
the main pack. The 12V Aux battery is a different story.

I designed the system this time to run off a 12v main relay for one
simple reason, auto cutoff when the Aux battery system gets too low.

This device will keep ALL of the batteries from draining to
….death. How you ask…?
This “battery Protector” is connected (via the main key switch) to
the 12v pack and will shut off when the AUX Headway
pack drains to 11.3 volts. Well before any damage can occur.
Sooooo, if I leave it on, that device will cut off the
12 v system which will cut off the main power pack too.

OK Ed, what if it drains too much during the ride?

That should not happen since the battery pack will
run the 12v system for well over 2.5 hours even if everything
was on. That would be the headlight, horn, taillight,
all the relays….etc. (Which would not happen….ever.)

AND (my favorite part) a switch was added to the
system that will allow me to tap the main pack and
energize the main contactor (which also energizes the
controller) so if something does go awry, I can still
“limp” home and not need to push my favorite ride.

■■■■■ proof EV? Time will tell.

50 days and counting…

3/11/11 Update: That’s the brakes ….Kid.

We started to wire up the brake lights today.
The hard part will be where to put the old school
brake light, but we will save that for another day.

What do you do if your racing master cylinder does
not have a Brake light switch? You add these little devices
and use the pressure of the brake line to activate the
brake light. It replaces the flow bolt.

That and a brake light flasher, and we are in
business! I also started the schematic on all of this
wiring job. I will post it as soon as I get it completed.

So far it is all in my head….scary!

49 days and counting!

3/12/11 Update: EV Spy Photo?

Dateline, Summerville SC.

An old/new Electric motorcycle was spotted on the roads
in a small neighborhood in South Carolina today. We
tried to get our cameras out to get all of the dirt, but only
got one shot the flying EV.

“I can see myself getting in trouble
with this motorcycle” stated the rider.
(Name withheld by request)

“This new Motenergy (formally Mars) motor has quite a punch.
Very smooth power all the way through the torque band.”

Although the rider would not answer any more
questions, the smile in the helmet said it all.

48 Days and counting!

3/13/11 Update: Testing the setup.

I took the Juiced Café motorcycle for some serious testing to check the load on the battery pack.
It accelerated very well and the lowest I got on a non-fully charged 72 volt pack was 63 volts (full throttle), well above the 2 volt per cell danger zone.
The final ride will have an 86 volt pack for starters and then a 90 to 102 volt pack depending on my need for speed.
For an older bike (1979) it handles extremely well. I felt very confident in the turns and never felt out of control.
I have ridden a 91 GSXR with the same confidence, and this is a 32 year old motorcycle.

Balance is the key. All of the parts we add are placed that way for a reason.

47 days and counting!

3/14/11 Update: Slow night.

Not much got done tonight as I have work obligations to attend to. I did get a set of foot pegs made
and mounted for a better riding position.
I also took measurements for a friend who will be helping out with the decals for the fairing and tank.

From the example he sent me, it should look great!

46 days and counting!

3/15/11 update: Now for the other stuff.

All of the bikes we have built so far had seats, fairings and other
items that came with the bike. Not so with this racer. We
have new period correct fiberglass from Airtech Streamlining
we need to mount and make work with my 6 foot tall frame.
This needs to be a light weight racer and still be street legal,
and not “sort of” street legal. I want all of the 4 wheeled drivers
to SEE me on the road.

Tonight I started on the seat pan, rear plastic fender and tail
light mount. I also have to find a person to make a comfortable
but light weight seat for the café racer seat.

45 days and counting!

3/16/11 Update: Step back and take a break. (and look for some parts! )

I did do some work on the charging circuit, but need a break. We will be going to Myrtle Beach this weekend to look at a Electric Bus system for our
Community development project we are starting later this year. It is made by Proterra.
Proterra., Inc
They are based in Colorado, but have a plant here in SC. We will also be hunting a seat cushion as well as a few small
period correct parts at a large car/motorcycle show. Photos to follow.

Some new small volt meters (one for each battery box) will arrive tomorrow and I may mount them up before we head out of town.
There is a great place for them on the fiberglass racing tank.

This is about as close to a Battery monitoring system as it gets for me. I will be able to tell if a particular box has an issue and troubleshoot if necessary.
(or just swap out the box) :slight_smile: They are waterproof, extremely light and are a two wire setup. Fun stuff!

44 Days and counting!

3/17/11 Update: Voltmeters everywhere.

I received the voltmeters and installed them into the fiberglass
tank top. They will not easily be seen by the spectator
right off. They will provide excellent info to the rider.
The first one in the photo is connected to an old 12v
battery so you get the idea of what they look like.

Their reaction/cycle time is very quick so I should be
able to get a good load reading during a run and see if
there are any problems starting to creep in.

I am going to connect one to a pack over the
weekend and see if there any measurable drain.

At 3mv, I do not think it will a problem….we will see!

43 days and counting!