Started designing the new box where all the electronic components will be moved. Since the Met plastics donÂ´t have any room for stuff up on the front frame I have to move everything that originally is inside the battery-box somewhere else.
The only place on the bike where there is some leftover space is behind the gas tank. You get a sizable gap between the front frame and the motor when you stretch it. So there will the electronics be moved. I have been thinking of how to solve this for a long time. I want the bike to be essentially waterproof since the bikes sits in my backyard in all kinds of weather. So I have to make a box that will hold everything and that protects everything as good as the battery-box does.
This is the space I got. 16cm wide. The bottom plate will be 16cm x 23cm. It will be bolted to the crossbar. I will also probably have to fasten it somewhere else to get 3 fastening points.
This is a mockup I did to size up everything and see if it would fit in the space I have. Luckily it does. It looks really messy here since I have removed all the tape around the harness. This will of course be cleaned up.
I have to reorganize everything and make new attachments, holders and brackets for everything.
The bottom plate will be in 5mm aluminium for strengt and to save weight. It also gives a solid base to bolt it to the crossbar on the front frame. The rest of the brackets that holds all the components will be made in 2mm steel.
I have made this simplified 3D model of the location of everything. The sizes of the components are generous and is only the outside dimensions. So even though it looks really tight in there. It will actually be enough room to get to everything.
This is only the inside of the box. There will be box sidings around it and a lid on top. Red = ECUBlue = Battery Yellow = Fuseholder/starter relayGreen = Relay holder x2
Grey = Blinker relay for ledsPurple = Tilt sensor Orange = Resistor for something Teal = Resisor and led driver. Gas and temp light
The space between the ECU and everything else will be used to for all the cables going through the box.
All the white parts are brackets and holders with holes in them to save weight. This is just a sketch of it. Not exactly how it will look when itÂ´s finished.
What do you think about this solution?