Saturday, October 26, 2013

Friday, October 25, 2013

End of Season Track Day

The last day of riding season had to come around sometime. We were fortunate to have such a great final day at MACtrack! Jackson was able to borrow a pair of leathers and ride Mk. 4 on the track for the first time. We also had the chance to get some very useful information on the tires we should be using. The Dunlop racing slicks we had been using were just too hard of a compound for our lightweight bike to keep warm, so we experimented with a set of DOT approved tires and a pair of rain tires (donated by one of the awesome supermoto guys we've gotten to know this year!). The rain tires ended up being the best gripping tire we have ever used, and made a significant improvement in the bike's ability to handle cornering at high speeds. Learning all of this before the end of the season will be critical for the upcoming "build season" for the next race bike (more details to come).

Tuesday, September 10, 2013

Sorting Out Problems the Old Fashioned Way

The Race bike also does double-duty as a commuter in the off season. Great way to find out the problems in the long-term. Like wheel bearing failures from crushed axle supports.



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Sunday, September 8, 2013

New Website Address

The team website has a new address, farfleracing.com, and the bike now has homemade vinyl decals for it. Special thanks to Don at Tekbots for letting us use their stencil cutter!

Monday, July 22, 2013

Refuel video, and Horn Rapids Trackday update

We are finally done with our REFUEL video, and had an excellent trackday at Horn Rapids in the tri-city area of WA. Long drive to get there, but very worth it. Lots of folks there to race with, and MK.4 performed flawlessly despite the 105+ degree heat. A last minute suspension adjustment helped chase keep it shiny side up the entire day, breaking a 6 trackday crashing spree.



Here are some pictures from Horn Rapids:


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Monday, July 1, 2013

REFUEL Pictures Posted

We've posted some of the pictures from REFUEL on our Facebook page, go check it out!

Refuel update

REFUEL was both an amazing, and challenging day. We started out pretty rough with the liquid cooling system getting stuck on and over flowing onto the back tire, causing us to crash. The rest of the day went better. We switched to the backup cooling system, which also failed, and then resorted to disabling it completely, and limiting the power to keep the motor alive. Because of our limited battery capacity, we were only able to do two to three laps of the track, so we had to cut short our sessions. But towards the end of the day we had turned a fast enough lap to place third behind Brammos TTXGP bike, and a heavily modified zero S. Needless to say we were pretty happy with that result.

Tuesday, June 25, 2013

Motor Rewind Photos

We got the motor rewound in record time! Jackson worked from 5:30PM to 1:30 AM last night to finish the rewind. You can check out the rest of the photos here

Monday, June 24, 2013

Motor Rewinding

It turns out that we need to rewind the motor before REFUEL, and there isn't any time to waste. We've already taken the old windings out and put in the new Nomex paper in preparation for the new windings to go in.

Sunday, June 23, 2013

MAC Track

MAC Track was a success! There were a lot of challenges that popped up, and we're going to be really busy this week making sure we're ready for REFUEL at Leguna Seca. There are a ton of photos and videos to go through, but little time to do it! We will try to get everything available ASAP!

Wednesday, June 19, 2013

Repairing the motor

The plan of attack to keep the axle from spinning in the stator without being able to clamp it in the mill was to drill holes that cut through both the hard steel axle, the stainless steel sleeve and the aluminum center stator support. Then we pounded hard knurled steel pins into the holes, and welded all of it together. This should help the motor stand up to the  one hundred plus foot-pounds of torque that this motor dishes out.




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Progress With the Liquid Cooling System

The screen enclosure for the liquid cooling system is almost finished, just need to mill the lexan faceplate and paint it.The top line is for the infared temperature sensor that is pointed at the outside of the motor, and the second line is for the thermistor that is inside the motor (not connected in photo). When the temperature gets above a certain level a pump gets activated and sends water inside the motor, where the heat from the motor will turn it into steam, which will escape through the side vent holes.

Too Much Horsepower!

Towards the end of our Santa Cruz trip the bike stopped working. Scoping the hall signal outputs it was determined that a hall sensor had been knocked loose. After tearing into the motor, we found out why the motor stopped working, and it wasn't good news... The axle twisted in the center aluminum stator support. It was only stopped by the hall sensor being pulled out of its slot, confusing the controller. After that happened, the two broken shear pin pieces beat up the ends of the lam stacks, luckily the magnets kept it contained to the lams, and they left the windings alone.  Should be fixable by mac track on Friday. Hopefully.



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Tuesday, June 18, 2013

Dyno Tuning the New Controller

We've got the bigger Sevcon controller installed and tuned thanks to the guys at Zero! Here's a video of the final run on the Dyno:

Monday, June 17, 2013

A fresh new Italian 415H racing chain has been put on, and the new controller has been installed! It is running only 70% power until we can get it on the dyno tonight. With the 420A controller geared for 100mph, it pulls harder than it ever did geared for 70mph with the lil 250A controller. Can't wait to get some numbers from it tonight turned up to 100% !






Wednesday, June 12, 2013

Getting the Suspension Set Up and Taking a Look at the Colors

Woo! The paint was pretty close to the leathers! Got Chase on the bike in gear and got the suspension sag all set up, and I don't think I'll have to trade any of the springs. Just a little shim to take up the unused 5 or so mm that is default on 2003-5 kyb forks.

Sunday, June 9, 2013

Bike is Back Together With New Rev Limited Top Speed

The bike is back together! And with a new top end rev speed limit of 104 mph!The Rev limiter is set at 3000 rpm. 30-72 gearing on 415 chain. The new controller (size 4 sevcon, thanks hollywood electrics!) should be making about 270 lbs of thrust with this gearing. 6G isn't half bad!

Friday, June 7, 2013

Re-Assembling the Bike

Getting closer... battery is back in the frame, re-doing the wiring harness tomorrow.

Wednesday, June 5, 2013

Frame Has Been Painted

After getting it back from the sandblaster, we were able to paint the frame! You can check out more pictures from the process here.



Tuesday, June 4, 2013

New Motor Bearings and Paint

Progress being made, the motor has a new set of bearings, and a fresh coat of paint. And the frame has been delivered to the sandblaster, when It gets picked up, It will get some paint too.







Sunday, June 2, 2013

Swingarm Changes and Frame Painting

We've taken the bike apart so we can paint the frame and add some more support to the swingarm. Unfortunately there was about 6 oz. of water that came out when we turned the bike upside down, so we'll need to dry out the inside before we do any painting. Also replacing the old dropouts with ones that are shorter and thicker.




Monday, May 27, 2013

Registered for REFUEL!

We are registered for Refuel at Laguna Seca Raceway!
Thanks to all who donated to make this possible!

Sunday, May 26, 2013

Android App Update for Wireless Telemetry System

We've finally got an update ready for our wireless telemetry system! This will allow us to send the data from the Cycle Analyst and liquid cooling system from the bike to our phones, which should let the rider focus on racing and let the rest of the team monitor the bike.


Information about the build can be found here

You can also download the app for yourself, all you need to connect is a bluetooth serial module, as described in the above thread.

Friday, May 24, 2013

BMS Installed and Working

The new battery management system is installed and working perfectly, as well as the side switchboard!


Tuesday, May 21, 2013

REFUEL at Laguna Seca

We are registered for refuel at Laguna seca!!!  Can't wait to get down there and turn some heads in the prototype class!

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And whoever just hit that donate button, in the corner, and tossed ten dollars to the team, THANKS!

That's the first donation the blog has ever had, and you just helped us pick up some badly needed rear brake pads!

We are on Hackaday!!!


Electric motorcycle hits the racing circuit

Holy carp!

To all who are viewing from Hackaday, check out some of the earlier pages for info on the home-built motor, and the frame build!

And in other news, we have some bolt on horsepower that showed up in the mail! we should now be running about 44hp and 300ft/lb to the ground, which is a BIG improvement from the 24hp and 120ft/lb we did on the dyno Here .








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Sunday, May 19, 2013

Fork Upgrade and Battery Repair


Lots of news, after the bikes first track day at PARC, it was determined that we needed a new fork. We soon found somebody in redmond that sold us a 2006 wr250 inverted fork, which will make an excellent upgrade from our 1989 yz125 fork.



and today we finally weeded out that annoying leaker cell, in the battery pack, and traded over the 10Awg spaghetti of loose tangled bullet connectors to some 1x50mm nickle plate copper sheet and ring terminals.

While the pack was out, we also re-mounted the contactor on the battery tray.  So now it can be unhooked at the controller, and then just drop the battery, bms and contactor down all at once. Makes it much easier to get at the pack for maintenance or upgrades.