Rad Rocket

It was time to give the rad bike a new look. Before I was just strapping shit onto my bike and putting it together as I went along, but after I completed the prototype, by duct taping everything on and 3D printing some mounts for the controller and  batteries, it was time to make it a completed unit. Do make a note that I had already put about 2000 miles onto this bike before building the case for it. 

I started off with modeling the down tube and seat tube of the bike on SolidWorks. This gave me an idea for the space I was working with. I also had remaining CAD models of both battery packs from Fusion so I brought them over as STEP files into SolidWorks. Now that all the parts were in, I created a Master Part for the frame and this took some time as I had to make precise angular measurements for which I used an Digital Angle Indicator. My main goal was to create an accurate model of the Down tube & Seat tube area so that I could design a case that slips onto it from the top which would be a lot more secure as it grips around the square down tube section. So I got to modeling the Trapezoidal Case and I ended up incorporating many features into it as I was going to 3D print the outer shell (15% infill & Adpt Cubic Pattern for 3D Support) , then Rivet in Aluminum Plates into the sides for structural support, rapid internal cooling, as well as using less filament because most of the area is the Aluminum plate and not the 3D printed Shell. 

Features that were implemented into the Case

• Guide Slots for the Aluminum Plates & Rivet Holes

• 2 Charging Ports

• Battery Level Indicator Slot on the top cover

• Side Support Areas for slotting onto the Down tube

• Mounting Clamp that I designed

• Rear Battery Riser (In case water were to enter the case, battery wouldn't soak up on the bottom

• Internal Drain Port

• Zip tie mounts to secure the battery down to the Shell

• Ignition and Throttle input slots

As the prints were being completed, I started on the aluminum panels for the case. I used an eighth inch aluminum plate and since i don't have a water jet cutter, I had to go old school on the table saw. That machine is absolutely terrifying but I scribed all the sides and manned up to cut that panel.

After all the prints were ready and the panels cut, It was time to start putting the pieces together. First came the bottom shell, then the panels, the top & front brackets, the top cover, and finally the rivets to secure everything in place. Below are images of the process.

Now that the case was completed, it was time to install the two batteries and controllers internally as well as wire everything up in such a crammed area. I ended up cutting any excess connectors I wasn't using on the controllers as it was taking up valuable space then added foam padding along any sharp corners and hard surfaces to prevent any damage to the battery. After installing everything all that was left was to plop the 3D Printed Cover on and call it a day.