1985 Honda NH80

(Purchase price $0)
 
 
This is my Honda Aero 80, also known as the NH80, without the seat, gas tank, rear wheel and suspension, and the engine, of course. I like it better this way. It was originally given to me for parts for the Honda CM400A conversion, specifically the CVT, but there was no easy way (that part is critical) to adapt it. I did look at other CVT's, but the direct drive chain worked out well. It worked so well in fact that this conversion will run by chain as well. Doubt there was ever a better candidate for conversion to EV. This scooter was powered by an 80cc 2-stroke, and it polluted, a lot. I drove it a while as it was really good on gas, but the gas it did use seemed to go right out the back.
 
The parts, so far:
  This was the first piece I picked up. Supplied to me by Jim, at Hi-Torque Electric. The purchase price was $300. I would have liked to use an Etek again, but its diameter was just a bit too big for the space in the rear wheel well*. Another candidate was a Lemco from the UK, but with its $1250 (US) price tag the decision was made for me. The only down side is I don't know a lot about this motor. It apparently came from a forklift, can handle just under 5HP continuous, likes high revs, is painted a kind of red-orange colour, and weighs almost as much as I do. (OK, a lot less than I do - 45 lbs). It's also just the right diameter to fit above the rear drive arm. The trick will be welding a bolt surface to the drive arm (below), and welding a face plate to that.
The next piece I picked up was this battery. I got it from Edmonds Batteries for $60. The regular price is about double that, but apparently this one has been sitting on the shelf for a while. It's a Sota XSA12550 Sealed Valve Regulated Lead Acid (VRLA) battery, and according to the manufacturer the electrolyte is AGM. It's rated for 55 Ah (20 hour rate) and its stated purpose is deep cycling applications.  
  I decided early on I was going to roll with 36V, as 48V turned out to be a lot of motive force on even the bigger CM4 frame, much more than I needed. In comparison the Aero frame weighs next to nothing, and there's not a lot of room for batteries. This battery is group 22NF - about 5 1/2 inches wide, and fits perfectly snug next to the side foot peg. So much so I'll probably only need one metal strip around the side to hold it in place. That leaves the third battery, which is shown in the middle mocked up in cardboard. This doesn't leave a lot of leg room, but I can't see anywhere else to put them*. Some molded plastic on the sides in front of the batteries might improve the look. The only alternative would be smaller batteries, such as the U1's, but they're 38 Ah. I also looked at lithium, but the only ones I could find locally were the slicboxes. Each 12V-equiavelent lithium box is very expensive. I was quoted $700 by a local dealer. These lithium boxes are about the same size as a 22NF battery, but roughly 1/3 the weight. I also considered NiMH, but couldn't find anything but very small cells for sale.
The pieces to purchase next will be the drive components: front and rear sprockets, sprocket hub, and chain. I realize the CVT is built into the drive arm, but there's no way to get at it, easily, that I can see. So decided to ignore the CVT, and chain drive it on the other side. The question there is how to mount the sprocket with enough clearance to get by the tire. All of the sprocket hubs I've seen don't have a lot of depth, so most likely it will need to be welded with a spacer. It would be nice to drive off the rear axle, as with the live axle gokart system, but the drive bolt is not long enough on the scooter. It's just long enough to hold the rear wheel and bolt.
 
    
For now, total spent is $360. Still required: 2 more batteries, controller, contactor, and drive components. As always I'm open to suggestions on how best to electrify my ride.

 

* A converted '84 NH80. Although the lower battery wouldn't have fit this way for the '85 as the frame construction is different (unless I cut part of the frame away in the centre - anyone know if this would be a really bad idea?), the ETEK might have.