I started thinking that perhaps I’d be better off in my initial build if I used something simpler than a collection of 22 premium cells. So following the lead of others, I’ve opted instead for six twelve-volt glass mat batteries of the type used in scooters and power chairs. This will get me the 72 volts I need to power up my system. They will be smaller and lighter than the LifePO cells and easier to place in the chassis. If I make a mistake and overcharge one or suck it dry and kill one of them, replacements will be readily available and not so expensive.

These are only 22 amp hour batteries, but they will allow me to get all the other systems built and tested for a lot less than most other alternatives. Less than $300, shipped!

Once the bugs are worked out, I’ll be in good shape to plug in the final battery solution.

I’ve decided to make some changes to my approach on this build that will allow me to move the build along and reduce the potential cost of my learning curve. First, I’ve decided to do my own welding. I have never welded before and I do not expect to become an expert. I just want to develop enough proficiency that I can do my own prototyping. If I were better skilled at CAD/CAM applications, I could do a lot of computer modeling and mock-ups. I’ve seen some other guys do some great work in that regard.

For things like this, I’m more of a hands-on guy. I have to bend the metal and fit it up in order to really see what will work and what won’t. That kind of approach would not work well if I were to go to a professional welder. So this will allow me the freedom to mess around with the layout and design until I get it the way I want it. If I need to take my prototype to a welder later, then they’ll have something to work from. But if I get just good enough, maybe I can skip that step altogether.

I’ll be dealing with mild steel, 1/8 to 3/16, so I chose this inexpensive flux-core welder from Harbor Freight. $115, shipped. Based on what I’ve read, it will be enough to get the job done.

On December 11th of last year, I ordered thirty 100 amp-hour lithium iron phosphate batteries for my project totalling a shade over $4200 with customs and shipping charges. Shipment was promised by early February. When early February came and went, I contacted the company and was told to expect them in “about 3 weeks.”

This scenario has played out multiple times now, but the response has been different each time. And now, the company has posted a “going out of business” notice on their website.

I’ve filed claims with everyone who’s been a party to this transaction and so far, American Express has responded with a credit for the full amount, pending a review. If it holds, the only setback I’ll have encountered is a few months lost time. And a pair of soiled pants.

Keep your fingers crossed!

I’d like to ask for your ideas, comments and suggestions as I put this together. This video explains what I’m doing.

The image above is just a screenshot. To view the video, please click here. Please and thank you!

I have a lot of other parts to procure, but having the motor and controller makes me feel like this project is on its way to completion.

My next project for Whitehorse Press is a title that will explore these types of trips. I want to give readers a head start in mapping out successful trips that by any standards would be considered “lifetime rides.”

What would you consider an ultimate North American journey, or what trips have you already taken that fit that category for you? What made them an “ultimate” for you?

This edition will contain five new loop rides and two new basecamps. Four rides and a base camp are in Ohio. I’ve added Bluefield, WV and a new ride in that area.

Perhaps more significantly, the new edition contains a lot of new pictures, and not just mine. I asked Journeys readers to submit some of their favorites and I got a lot of great pics. I think the pictures taken by others adds a fresh perspective and I’m looking forward to seeing the new edition in print.

In order to reach a minimum of a 72 volt system, I had to fit 22 batteries on board. Fitting 26 gets me 84 volts, 30 gets me my desired target, 96 volts. The batteries I plan to use are 100 amp hours. It’s common in many conversions to use smaller batteries, more like 60 amp hour. I’m aiming for a comfortable 60 mile range so I can run down to visit clients in the District without worrying about having the juice to get home.

My initial conclusion is that I can fit 22 batteries comfortably, 26 if I finagle a few things, 28, maybe 29 if I relocate the controller. I am going to take another shot at it later, but I am currently considering placing 22 in the main compartment, then locating the remaining eight in custom-built containers in the back, four to a side.

The next time I conduct this exercise, I’ll start by placing batteries from the bottom up instead of top down and see if I get a better result.

Once I get a better idea how I want them to go in, I’ll begin fabricating a prototype battery cage and motor mount.

Cutting the tank requires some care. After emptying the tank of gas, I washed it out with water several times. I let it vent for a while before I started cutting. I used a Dremel with the 1.5″ quick release cutting wheels. This gave me precise control over my cuts. After a while, when I was pretty certain it wouldn’t blow up, I felt comfortable letting my son Carl take a turn. Cutting? Yeah, that’s a fun thing.

At this step, it’s a good idea to wear protective goggles. The Dremel disks distintegrate as they cut, throwing metal filings all over the place. There’s a lot of metallic dust in the air, so if you’re sensitive to that, a breathing mask is a good idea, too.