EpsilonZero
...still cheaper than a boat!
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- Reaction score
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A few weeks back, a new member (soilsamplerbill) was messaging me regarding motor controllers for his build. When he was talking to Fany at Kelly, he was asked if he wanted field weakening on his KLS-H controller. Now, it turned out the KLS-H line doesn't support it but the KLS-N line secretly does. If you ask for it in the notes, you can get a controller that, along with special software, supports field weakening. So, I decided to order a new controller because I already bought two to three versions of everything else on the kart, so why not upgrade the controller too?
First, disassembling...
I ordered it on a backplate, thinking I might be able to just affix the pre-assembled unit and save some time... Nope! The orientation was not good and components too spread out, making the whole thing too big.
Oh well... I don't have a bunch of tools for nothing. I mocked up a cardboard sub-assembly for the controller, battery switch, and charging port (you can see it under the white dustpan, with the started steel sub-assembly lying on the gloves. I left a huge open area to provide airflow to the back and sides of the controller.
Lots of cutting, welding, and drilling later (before I realized I forgot the charging port tab)... I like welding in direct sunlight or no sunlight with an LED light on top of my work. The latter maybe more because my eyes don't need to adjust with my cheapo mask.
I made mounting points from angle iron and bolted them to the sub-assembly. I used my extra hands (a thrashed tire set and a c-clamp) to hold the assembly in place while I welded the mounting points to the kart frame.
After I painted the sub-assembly, I realized I forgot the charging port and promptly cut the wrong sized hole while making the tab. (correct size hole not pictured...)
Here is the back of my completed sub-assembly.
And the front... Note the giant aluminum plate it came on and the old controller assembly.
<continued...>
First, disassembling...
I ordered it on a backplate, thinking I might be able to just affix the pre-assembled unit and save some time... Nope! The orientation was not good and components too spread out, making the whole thing too big.
Oh well... I don't have a bunch of tools for nothing. I mocked up a cardboard sub-assembly for the controller, battery switch, and charging port (you can see it under the white dustpan, with the started steel sub-assembly lying on the gloves. I left a huge open area to provide airflow to the back and sides of the controller.
Lots of cutting, welding, and drilling later (before I realized I forgot the charging port tab)... I like welding in direct sunlight or no sunlight with an LED light on top of my work. The latter maybe more because my eyes don't need to adjust with my cheapo mask.
I made mounting points from angle iron and bolted them to the sub-assembly. I used my extra hands (a thrashed tire set and a c-clamp) to hold the assembly in place while I welded the mounting points to the kart frame.
After I painted the sub-assembly, I realized I forgot the charging port and promptly cut the wrong sized hole while making the tab. (correct size hole not pictured...)
Here is the back of my completed sub-assembly.
And the front... Note the giant aluminum plate it came on and the old controller assembly.
<continued...>