Extending cable on Magic Pie 3

[TomP]

Hi there,

Newbs here and hoping the old hands might be able to give me some leads. I am building a standup scooter using an MP3 front wheel hub. Almost done except that main cable with 8 pin connector is short about 70cm. What do you guys think is best and simplest (you're dealing with an electro C- here!) method to extend cable? The 48v/10Ah pack will mount on diagonal part of the frame which attaches to steering tube. Pic attached below.

Thanks before for information and tips.

Tom

[Bikemad]

Hi Tom andto the forum.

My preference would be to put a cosstube along the frame to give it a strong backbone and then run the cables along it in a more direct route. Then you could fit a seat and some footrests for a more comfortable ride.



Alternatively, you could use a length of 8 core network cable to extend the front harness as shown here:



Try and make sure that the joints will end up on the part of the harness that can be strapped to the frame for additional support.

Judging by the length of the scooter, I'm guessing it will be used for carrying more than just one person. If this is the case, I would be very concerned about the strength of the welded joint on the steering tube and I would strongly recommend welding some triangular plates (or a piece of box section) between the steering tube and the diagonal part of the frame to strengthen the joint as shown here:


I think you should reinforce this joint anyway, just imagine what could happen if it suddenly failed while you were travelling along at 20mph. 

Alan
 

[GM Canada]

I find it humorous I answered the same question in email with the same answer. Except my answer did not come with diagrams and pictures , plus other suggestions and safety concerns. You are the best Alan!

Here was my reply...

"There are no extension cables. You have to make your own by cutting your cable and adding a length of wire in between. I use network cable most often as its flexible with many wires inside. I think its rj45 cable. Try to buy it with a black skin or run it in black shrink tube.

Enjoy the Ride!
Gary"

[TomP]

Thanks a lot for the great information to both of you! Super helpful. I'm building the scoot to take my son (the young'n in the foto) to school along the beach. We don't have a road to our house and often the waves on the beach make it difficult to take him by boat. Its about a 4km ride one way. Nice idea on the cross bar though I'll have to work a seat for 2 in there. I'll also put some reinforcing up where the steering tube is.

Thanks again fellas!

[TomP]

While I have you brainy guys there, and slightly veering off subject, does sending DC charge from battery to MP3 via such small gauge cables not result in voltage losses?

Cheers

Tom

[Aliasssss]

Hello mate.

Sorry for the late response. I hope you understood to use the patch cord cable (ethernet cable, RJ45 plugs at it's ends). Inside you will find 4 pairs of wires, that is 8 in total. You cannot use the ethernet cable to extend the motor to battery cable. That cable must be of a different gauge, not sure but I thing 14 AWG will do, 12 AWG won't hurt anyone! It needs to have at least 2 square mm of threaded copper in each wire, that is if you only use the internal controller which maxes out 30A continuous. If you use an aftermarket custom controller maybe you need thicker wires.

Hope it helps!