The Phoenix - Rise of a RE44 to racing glory

Welcome people. This will be the story of “The Phoenix” - my way of a board just for racing.

This is going to be a really long story, you probably want to get yourself something to eat or drink :smiley:
First some information about myself, because it is the first time, I really do a thread. I am from Germany. Got my first production board in 2015 and was instantly hooked. I just loved the feeling. 10 years and many boards, riding & learning later - I wanted to get my first real raceboard to compete with the best.

The idea - How everything started

2020-2022

Everything started doing some sessions on a parking lot of an hotel during Covid, but nothing real serious. Just having fun with friends, measuring times with an oldschool system and some production & custom Evolve`s.
In Winter 2022/2023 I saw a post of @davidpilny on Facebook. It was a race event of Xerace in Prague. My best friend and I signed up for it.

Pics


2023

Esk8Con - Vegas

Right before the event in Prague in April, another opportunity showed up in this forum and I got the chance to race in Vegas for Defiant Board. Flights/hotel booked and off I am to Vegas. Spontanous. Really enjoyed the possibility and got so much input. Wasnt really successfull, struggled with the Boas urethane, still learnt a lot. Met many cool people. Filled sandbags with Mario and @fessyfoo, built the track with Socal - The Legend, folded many barriers. And also met @davidpilny for the first time in person. Just a few weeks ago, we were writting on Facebook about Prague :smiley: Also met @davidbonde for the first time, such an awesome person. But probably many cant remember this, but thats totally fine. For me, that was hugh. And at the end of the event, Moe gave me the possibility to ride on one of his V5s. It was such an honor to step on a real raceboard for the first time.

Pics




Pitland - Prague

It was just awesome and again so much input. I used my Flux DIY in the Open Category. Called “The Orkaan”. Never did a thread for it. Just a quick spec sheet:
20s5p - Spinted ESC - Radium 6485 - Matrix II with Riptide.
So not ideal on an indoor track with only sharp turns and shitty tires.
But my best friend and I were hooked. We met so many cool people, had an amazing aftershow party at our camper and we loved to compete.

Pics





Fast forward to the end of 2024

In June 2024 my best friend and I achieved our first podium/victory in the Open Category in Xerace Pardubice. But we only got it, because others were struggeling (looking at you, David`s V5). The last event in Prague in November showed me, my board is the limit. So if I want to compete with the best of the best, I need to get a real raceboard done. And I met a key person in Prague, who helped me a lot (got my board back on the road, after I fucked up with the VESC tool a day before the race in Prague) and most importantly is such a brain and great person @Dinnye. Another benifit, he is living really close to me. Important information for the development part, I am not good in building shit, especially electronics. Without the willing and knowledge of Bence, it wouldnt have been possible for me, to get this board so fast on the track. He was really patience and tried to help me with all my questions about parts.

Pics




The Development

First I want to give credits to my best friend Oskar, because he was a hugh part in developing and evolving every step of “The Phoenix”. I got a lot of inspiration and also help in this forum. @Tasventouras @Ash @Dinnye

The goal

Get a rolling chassis done as quickly as possible with these important points to achieve:

  1. Reliablity
  2. Easy to maintenance
  3. Lowest ride height possible, super agile, but still stable in a straight line
  4. Powerful battery
  5. 4WD with OpenGears for the possibility of a quick change of tires

December 2024

I got many parts over the years, always a build of a raceboard in mind. Inspired by many people and experience. But never really got it done, for many reasons.
A few examples:

  • 3-Link-Trucks from Moe
  • different decks + enclosures
  • ESC enclosures
  • Motors
  • ESC`s

Deck
Which deck should we use? I got a few laying around, but nothing would be a really good choice. Too small, not wide enough (I am a big foot), no real drop. Except one pretty beaten RE44. So lets get some epoxy and fix it. Done and another friend will give it a nice finish and design. Awesome. One job done, we are going to use the DS enclosure and everything will be good. I really dont like the look of a top mounted battery enclosure. Next step.

Pics



Trucks
@Dinnye was using Dualities and really loved these. After talking for a bit about the trucks and the way, they are working and how easy these are to maintain, it was clear, I need these. So I left the 3-Links in the shelf and wanted to order a set of Dualities. With the help of Dinnye and also @Titoxd1000 I got a set of 270mm Dualities as a Flatdeck version. He only had the raw version available, but I liked the look and in the end, it was the perfect call. In between, I saw the build thread of @Ash and his Archangle. That thing was a hugh inspiration and also Ash was super helpful with all my questions. So I ordered the exact same motor mounts as him of @IDEA. Because I really wanted to get my motors under the deck. That will not work out in the end, but I loved the idea.

Battery
What could we fit in the DS enclosure? 18s4p? Maybe more. Which cells should we use? Still not really sure, but it wasn`t necessary to descide it now, it is almost Christmas, so can decide it in January with Dinnye. But it was clear, it will be 18s.

ESC
So what are our options with an 18s configuration:

MakerX D100s - Not reliable enough :-1:
Spinted - had problems with it in my Flux :-1:
Stormcore - nooooo :-1:
SKP Solo`s - seems reliable, maybe not the most powerful, but perfect choice for our goal :clap:
Ordered two from @Skyart (one to put inside the enclosure and one with a separate enclosure to mount it on top)

Motors
I really liked my Radium 6485. I used these on my Flux. So I already had another set of these in the shelf. Bought them a long time ago, like many other parts. So I only needed the 6455 for the front. Ordered these from Radium. Another step done.

So I only needed to order a few bits and pieces, like a second set of Opengears & another drivegear from Moe and some other stuff. BRPs were already in the shelf. So at the end of December, I ordered all the parts to get my rolling chassis ready in January. Lets gooo. We are in time to get it to Dinnye at the end of January.

January 2025

Are we on the right way?

The first parts arrived and we started to put it together. First the deck and enclosure with the trucks. After talking to a lot of people in the last month about the ride height and the goal, to almost align the deck with the trucks and I also saw the different versions of Moes new raceboards, I wasnt happy with our outcome.. The ride height was way too high in my opinion and we would miss different goals. We wanted a raceboard without any compromise on the ride height, so how could we solve it?

Pics



Let`s get our visual preferences aside and think more pragmatic.
I got the following idea:

  1. Battery topmounted
  2. both ESC`s topmounted in the front and back (need to order another one)
  3. Cut out the front and back of the deck
  4. Mount the trucks “dropthrough” on an aluminium plate
  5. And get an aluminium support frame, which will be bolted on both sides to the aluminium plates - so the deck wouldnt crack and it has maximum stiffness

A day later and we were convinced, that`s the way we want to do it. So we talked to Bence and shared our ideas. Especially the possible structure of the battery + seize was important. What could be the maximum seize of the battery. More is better :smiley: Also our schedule was tight, the original plan was to get it done before Bence heads off to Vegas for Esk8Con. We still thought, it would be possible, but soon we will realize, nope :smiley:

How are we going to get it done?

Another big shout out to my best friend. Without him and his iPad I already would have been fucked :smiley: The following nights we were in my “Cave” and got a 3D model made for the frame and the plates. He was getting better and better at it. When he was done, he printed it in real seize, glued it on cardboard and checked, if he got the dimensions right. Full commitment. He added a channel for all the wires into the frame. So thats looking really promising, why dont we do also a design for the battery box. If we need to put it on top, lets make it good looking. On this part, Bence again helped us a lot, because he got the knowledge, what needs to fit in. At the end of January, we were ready to order the parts. I found a CNC-manufacturer in Germany. We still had one major problem, we need the parts as fast as possible. The faster = more expensive. Still it will take around 4 weeks to get the parts. And we also decided to skip the box made out of Aluminium, because way to expensive. We chose 7075 aluminium.

Pics









Another “problem”

We talked to Bence a lot about the battery and which configuration we will do. We also talked about my choice of motors. He mentioned an issue with older generations of the 6455 with high voltage. So I talked to @Tony_Stark about the issue and the solution in V8.0. Alright, fuck it. I dont want to take the gamble, I want reliablity. So I ordered a new set of the 6455`s. My 6485 should be fine, because the V5.0 was robust. But nevertheless, a new motor was just released, a collaboration of @fujio001 and Radium. The 6495 and I couldnt controll myself and also ordered these… :money_with_wings:

Pics


February 2025

Fingers crossed

As we were waiting on the aluminium parts and hoping, we did all the measurement right, we still had the issue with the battery box. So how could we get it done with a good and nice look to it? Without braking the bank. Again my best friend comes into the game and said, lets do it with wood. And also, lets keep the look of our 3D model. I was like, how? How could we get a bend like that? How can we cut that precise and get it in the right shape according to the deck?
His response:

  1. Right tools and right measure tools
  2. Cardboard
  3. Many Cuts, really hot water and pressure. Repeat.
  4. Screws + glue + pressure
  5. Finish + paint

A few night later, the box was done. Crazy.. Couldnt believe, how fast we were getting forward. Box was designed to fit an 18s6p battery and still wasnt that hugh. Was really happy with the result. We implemented inserts in the box, aligned & marked the position and drilled holes to bolt it from the bottom to the deck. Bence helped me to decide, which cell would be the best. We chose the BAK45D and ordered enough, so he can build it.
In the meantime, we were still waiting on the aluminium parts. They got delayed a bit…

Pics



















March 2025

The highs and lows in DIY

It starts with a low. We were having a closer look to the ESC’s. Our first plan was to put one Solo in the enclosure, so thats why I ordered one for this. But that changed and now we realised, fuck, how are we going to use this Solo with the top mounted enclosure? The heatsink of the Solo is a no-match.. We need to DIY the bottom plate of the enclosure and cut it out. Such a shitty job, but again together you can almost solve any problem. Aluminium is a pain, but we managed it.

Pics




Mid March I finally received the package with the aluminium parts and I was so hyped. The finish was just beautiful. I couldnt wait to get home and get started.
The deck was already prepared with the cutouts. We still thought, lets fit it to the deck, do some minor adjustments and get it to Bence in two days, maybe he will get it done easily. Later you will see, nothing was really easy..

But that was definitley too optimistic.. We pretty much instantly realised, we need more than two days to get it done and set up the rolling chassis. Different problems showed up. So we decided together with Bence, I will get it to him, when he is back from America.

Solving the issues

Let’s start on the positiv side. Deck and aluminium parts were a beautiful match. So no real mistakes in the general design. We drilled the holes for the inserts on the bottom, we took our time to do no mistakes on this side. Same on both sides with the top plate and the alignment to the chassis on the bottom. Drilled the holes and connected both parts. The wedding was complete. Now we bolted the drivetrains to the deck.

Positive:

  • we got it as low as possible, almost aligned the trucks with the deck
  • the deck wouldnt touch the ground even on full lean

Negative:

  • Our chassis was too good and beautiful. It was in the way of the trucks on full lean. On both sides..
  • The enclosures of the Solo’s are touching the tires..
  • The channel for the wires was too small
Pics









Solutions:

  1. Shorten the chassis and also cut into the side of the deck on both sides to get the full lean
  2. Spin the front enclosure and also lift both enclosures.
  3. Cut out even more of the deck for the wires

We still were confident, that it is strong enough even with our plans. The structure as a sandwich gave us the confidence. After hours and days of adjusting the chassis and deck, we finally got the full lean without touching between hangar and deck :partying_face:
In between, I ordered the “right” bolts and spacers to lift the enclosures. That worked flawless and another issue was solved.
As we were mounting the trucks to the plate, Oskar realised, we achieved another benefit. If we would use the right bolts, we could get the trucks off the plate without taking off the ESC enclosures. And that’s a hugh benefit. To change the boardside bushing on Dualities, you have to take of the trucks to get to the kingpin. Another + on the maintenance.

Pics











April 2025

Esk8Con is done, Bence is on his way home and we just did the last bits and pieces. Installed a front binding and I am on my way to Denmark. Dropped the rolling board at Bence’s house and now Bence starts his magic. He wanted to get it done until Easter. So roundabout two weeks time and boy oh boy, it wasn’t as flawsless. But @Dinnye got it done and found always a solution. He probably could better explain, what issues he had to solve.

“The pick-up”
I can start at the point, when I was supposed to pick it up and get back. It was the Thursday before Easter. He told me to be at his house around 4pm to pick it up. After work, I took the ferry and went to him. Easy, it takes me around 2 hours, including the ferry, to get to him. Last ferry back was leaving around 6pm, so it will be easy to get back home. Unless some issues show up and delay the whole process :smiley: We had to print spacers and many other shit was still not ready, even with Bence’s dedication :smiley: alright, I will stay until it is done. Cannot really help a lot, but will stay to give mental support and another problem was: Bence will fly home to Hungary tomorrow. So no real other option. Told my girlfriend and kids, that I will sleep in the car and take the first ferry tomorrow. At 1am in the morning, it was done and raining… So no real option to test it, if everything is working. But I was believing in the magic of his work and was sure, it will be all good. So started my drive home at 1:30am, took a nap on half way and was at the ferry around 5am. I thought, the first ferry would leave at 5:30, but not on a holiday.. So another hour of sleep in the car :smiley: Still not knowing, that Bence also drove to the ferry, because I forgot my charger at his house.. Didn’t checked my phone until I was on the ferry… As I said before, Bence is a man of full dedication and support. He also slept in the car next to the ferry, but we missed each other.. He gave the charger to the people of the ferry and they took it on the next ferry. I was waiting on the other side and finally getting home at 9am. What a rollercoaster of emotions, but I was soooo happy. :slight_smile:

Pics















The first real testrun on the T-Race

Two days later it was finally happening, the first outing. And I was instantly in love and felt just perfect. Better as I thought it would be. It just felt right. First I was a bit skeptical about the setup of the trucks. I chose a real loose setup for the trucks and I couldn’t believe, it would feel stable. But it did, like on rails in acceleration. And in corners it would let me choose any line, really divey. The braking was in the beginning a bit difficult, because of this divey/loose feeling and also this was my first real 4WD board. So braking was something, I had to learn. But nothing scary.

It was such a relive, that every idea out of the development process worked out in the end. I couldn’t stop riding, had to do several sessions on the T-Race track the following days, always chasing another Pb and getting to know “The Phoenix” better and better. We also installed a binding in the back. I wanted to give it a try and it was another golden decision. I was just using it for stability and safety. Still moving my foot a lot.

Pics




May 2025

XeRace Prague

The biggest event of Xerace Europe history was getting closer and closer. 17th of May. The first competition for “The Phoenix” ahead. I was really looking forward to get to Prague and see,if it is possible for me, to compete with some of the best riders out there? Tas, Tucker, Dylan, David, Tilo, Vasek, Bence, Vik, David.. so many great riders and crazy boards.
Friday
Oskar and I arrived in Prague on Friday morning. One day before the offical race. David organized Kartplanet for practicing on Friday. The weather was not our friend in the morning, so it took almost till noon until we could slowly start to get out on the track. I instantly was really happy and everything was working. On the second run I was following @davidbonde and he was already pushing a bit. I was around 25m behind him on the back straight as he got a speedwobble in the transition of acceleration and braking. Scary.. He hit his head hard on the ground and I tried to avoid him, fell over him and flipped my board. But that wasn’t important, all the care for David in that moment, because that was a hugh crash. Luckily he “just” had a concusion, still couldn’t compete the next day.. But that showed again, how important good protection is in our sport! My board showed no sign of real damage, even the flip on the ESC enclosures didnt do any damage and everything was still in place. Built to last :smiley: at least until the next run. I felt really good and improved a lot. But I started to feel some vibration in the front.. Another thing I learned, always check the nuts of your tires… I lost 3 nuts.. I thought, fuck… We will never find them and I dont have enough spares with me.. but again Oskar to the rescue, he said, I will find them and he did find 2 of them :partying_face: Also one of my front BRP’s was bad, so we had to change it. @philo borrowed us an umbrella, because it started to rain. So we got everything back together and we realised, one thread of the rear drives was also snapped.. I had a spare with me, but how are we getting it out? Oskar said, we will find a solution, when we are done with practising. He said, try the new tire and check, if the vibration is gone. And it was gone and felt great again. After the session was done and everybody leaving for the city, we started to get this little problem solved. We got all the tools with us and were prepared for almost every situation :smiley: In the end, we checked every thread of the drives and almost applied on all of them new loctite, because all of them were loose.
So actually a perfect practise session before a race event, because we could solve all the issues,which would have been impossible on race day. Another hugh shout out to my best friend and mechanic Oskar :clinking_beer_mugs:

Pics


Saturday - Raceday
The Open Category was scheduled for the afternoon, so I could enjoy the morning watching other races and prepare my setup and myself. Also had a few nice chats with other racers. It was such an awesome atmosphere. And again the organisation of the whole event was just superior!
Quali went really good and I improved my times continously. Ended in 3rd position and was really happy so far. No issues, a lot of grip even with the wide Brp’s in the rear and my confidence was growing. At halftime, so after the first 3 races and the best 2 combined, I was in position 4. Close behind Tucker in 3rd. I was almost 4 seconds behind Vasek in 1st. Now we will change direction and I thought, I want to get on the podium. The victory seemed out of reach. But I wanted to push as hard as possible to get on the podium. My body felt still really good, no feel of exhaustment, so let’s go. I actually felt really relaxed.

Race 4 was a bit of a mess, Vasek crashed in front and DNF. Tas had problems with the grip and slowed the pace a bit. We were all really close together so it was hard to really push. Everybody was in the way of each other.
Race 5 This time I wanted to leave a bit more space to the guys in front of me and really dropped the hammer. Pushed consistant pace over the three laps, did no mistakes and it felt good. Did my fastest lap of the day also in this race.
Race 6 - Final race I was now second and Vasek was leading by 1,69 seconds. I cut the advantage of him in half and had to make up this time in the next three laps. Sadly he again had issues with the grip and slided out. In that moment, I knew, I need to push me as hard as possible and get that victory. And I did, I won the biggest event ever on my own creation of a raceboard “The Phoenix”. :trophy:
I couldn’t believe it… And just as everything was cooling down, we still had the “Dragy Challenge Race”. A Head to Head race. The best 10 riders of the event doing a 5 lap race with a standing start. That was also my first ever full power launch on this board. Starting from the Pole Position, I managed to stay in front and kept it till the end. Again it felt absolutly right, everything. Like a pair of shoes. The board wasn’t fighting me, gave me confidence in finding the limit of grip and always ready to do whatever I wanted to do.
I just secured a double win on the biggest event ever in Europe. Still feels like dreaming.
Another awesome result achieved Oskar in the Open 2WD Category and also secured the victory!! We couldn’t wish any more! :tada: Also he got on the podium in the “Street Category” :tada:

Pics







Summary of “The Phoenix”

Thanks for reading soo far!
Mission of Development completed so far for this season! And my fire for racing is burning. I want to win the whole season of XeRace 2025 now.
I achieved the following results in the next races:

  • Pardubice I had to skip sadly :cry:
  • Budapest - 2nd
Pics

  • Paris - 1st (a lot of awesome footage available)
Pics




At the moment I am leading the championship with 68pts over @davidpilny in 2nd with 58pts. Two races left in Brno and the final race again in Prague. I want to stay in front and win this championship :grin: Sorry David.

Again a hugh THANKS to Bence and Oskar, without them, this wouldnt have been possible! Full credits to you guys!

Specs and list of parts (that’s what everybody really was waiting for)

  • RedEmber 44
  • Duality 270mm trucks - Centerset in the front - 40/15 angles
  • Front: WFB Tall Barrel 93a / Rear: WFB Tall Chubby 93a
  • 18s6p Bak 45D by @Dinnye
  • SKP Solo’s
  • Radium 6455’s 138kv V8.0 & Radium/Mad 6495’s 145kv V8.0
  • IDEA Motor mounts v11.3
  • SRB Drivehubs & Opengears 67/21
  • BRP 3" wide x 6" & 4" wide x 6"
  • Zmote Trigger

As always, I want to improve some stuff at the end of this season, so the board hopefully gets even better. I am already planning a few things and will keep you guys posted in this thread. It won’t be as crazy as Bence’s thread, but still interesting. And I really hope, we have a BOTY 2025 award :smiley:

Cheers!

19 Likes

Ah somebody is awake too :smiley: Love to read all the backstory! That was a hell of a work to get there. That ferry intermezzo is crazy :smiley:

Btw definitelly remember meeting you over the sand table on esk8con :-D:-D Was interesting to meet a random guy from Europe there :smiley: Great story and great to see your passion that did not leave even after the failed old Pitland with no results available. You were probably the happiest person that day :smiley: Even your double digit xErace vest is a proof how long you are here. Cool to see you evolve all the way to the top and visit more races :smiley:

Even with Pardubice I was just starting my Stooge experiments back then. I always said it was and probably always will be a big part garage race and thats a part of it. It definitelly paid off for me the rest of that season as it does for you now. But I believe its a great satisfaction when you finally won on your own terms. I always thought that not getting the podiums motivates you even more and its cool seeing you this year becoming a real threat to anyone and coming for the crown :slight_smile:

Thanks for being part of our great European journey, its always a pleasure!

5 Likes

Dang, this is a sick build!! I love the creative problem solving.

It was a blast racing with you, and had no idea I was racing against such a sick board! You were fast af, definitely earned those wins.

Awesome threads like yours here is what keeps me coming back to the forum.

This is sick. I think I’m going to steal it

Interesting… What’s the issue?
Nothing fancy is currently running SKP 6455’s at 20s… there’s been weird behavior every since I installed them that I haven’t been able to fix. I’ve always assumed it was a vesc config problem(skill issue), but I wonder if it’s this motor issue.

5 Likes

amazing tale. congratulations!

incredible build.

3 Likes

:clap: @Dinnye

5 Likes

Damn what an epic build!!

those aluminium parts are thicccc

forgive me if i missed it, how much does this bad boi weigh?

2 Likes

Thanks mate.
It took me a long time to finally get this thread done, but I agree with you, I love to read these build threads, especially from other racers. I learned a lot just because of that.

4 Likes

Go for it, inspiration and „stealing“ each other ideas gets us forward.

1 Like

My understanding was, prior V8.0 was something in the motor not in the right seize and could cause cutouts in combination of highvoltage and max acceleration. Also in a worst case could power a spike of energy back into the ESC and fry it. But probably @Dinnye or @Tony_Stark are better in explaining the issue :joy:

Very kind words my friend and competitor :clinking_beer_mugs: I am so proud, being part of this journey and met all these awesome people.

2 Likes

Thanks Fess :chequered_flag:

1 Like

With the 6“ BRP’s = 29,7kg :feather:

2 Likes

The reason why I told Hendrik that the 6455s aren’t that great was that exact behaviour on Nothing Fancy that I got to test at the Dam! :smile: Hendrik just wanted to get a bulletproof setup that didn’t have any issues, so I recommended to skip the 55s. I also talked to Vik who said the 55s do weird stuff and cutouts at high amps, and actually Flipsky 54s can do higher amps than reacher 55s because of this.

Regarding the versioning, not sure if this high amp issue is fixed or not, what my untested hypothesis is that reachers have lower inductance compared to flipsky and this means that the VESC algorithm has a harder time tracking it and the current loop needs to be faster to keep up, maybe VESC detection doesn’t compensate for it enough. And I don’t really feel like tuning the VESC PIDs myself. Also smaller motor should mean smaller inductance, so go too small with a low inductance motor to begin with, and VESC has a hard time to keep up. And going high voltage doesn’t help these issues either. To make sure we don’t face these issues I setup the 55s for only 50A each if I remember it correctly, and they run without any issues. Hendrik has relatively low KV version (140ish), it’s setup for around the same shaft torque as Nothing Fancy motors at 60A (because 60A was working without issues at the Dam when I borrowed your board (thanks for that again!)). If my hypothesis is indeed the reality, then this probably isn’t fixed in newer versions either.

What is definitely fixed with the new version (v8) is sensors. Since I heard the potential issues of older gen Reacher sensors, I was vary of hooking them up, and suggesting v8 to Hendrik because he wanted reliability and sensored operation. Later I decided to hook up my own V6 sensors to my D100S and blown that D100S within the first ride with 200A pulls (6495 175kv), that was in May right before Prague.

3 Likes

is this a place where bumping the zero vector frequency up helps?
I had to do that on the lilttle focers from 20 to 30 khz(?) on earlier reachers. and it behaved much better. (no more overcurrent faults. )

@Esk8Cave it’s an epic board and I am excited that I could help building it! And the thread was a great read! :fire:

3 Likes

Maybe? To be honest I didn’t play with it. My ~170kv 75s 85s and 95s all behave well on default settings.

I’m sure someone who is an expert could tune the reacher 55s to work well with some effort put into it, vesc default tuning doesn’t seem to like it at high amps. But I never actually did manual tuning on VESC for a specific motor. I didn’t feel like going deep into advanced settings on a board that we couldn’t even test ride when it got finished is a good idea, I wanted to play it safe, make sure everything works without an issue.

2 Likes

Here’s some pics from the build process, of the 18S6P Bak 45D battery and the electronics assembly of the board.

I used the Glitter 811H welder, as the plan was 0.3 copper connections so that the battery pack is ready for everything, if the motors / ESCs get upgraded, the pack will still take it no problem. It’s a raceboard afterall - and my philosophy for raceboards is that the limit should be you, not the board. :grin:

This welder welds 0.3 copper + 0.1 nickel plated steel sandwich at 65% power with great results. The welds are incredibly strong. The 50mm wide 0.3 copper handles high amps like it’s nothing. Fitting 6 weld dots is actually pretty hard on the positive terminal, but more welds, better connection, can handle higher amps. Is it overkill? Yes. But in my opinion a raceboard should be built overkill.

The pack consists of 3 modules like this:

Given that this is the first big pack that I did with copper sandwich, this was unexpectedly time consuming and annoying to do.

Stacked side by side with fishpaper and FR4 inbetween as separation.

BMS fits on the side like this, wires are routed over fishpaper and double sided for laying them down nicely. Then black high temp hot glue to secure them. The 3 modules are connected with 3x 10AWG (my philosophy is that all internal connections must be able to handle higher amps than any external wiring). This way with cells this powerful if there’s any external short, it doesn’t damage the pack, the short just gets turned into vapour.

For terminals 8AWG goes to the rear ESCs and 10AWG goes to the front ESCs.

Now onto attaching the terminals:

Oopsie. I’ll share this little fail :smile: Accidently shorted the battery with the soldering iron tip for a bit (Hendrik, no worries, such a pack can easily sustain such things with no damage… And my everything must be overkill build philosophy is very useful for stuff like this). Lets say I simulated what usually happens when a D100s blows up :smile:

Such errors can happen even to the best of us, never skip kapton tape when soldering live XT90, no matter how much experience you have. I did it countless times over the well over 50 packs I made without shorting stuff, but it had to happen at one point. Given that this was the most powerful pack of them all, the aftermath was quite spectacular. I definitely learnt my lesson here, this was frightening to experience first hand.

The wire didn’t move, the missing wire got splattered all around my table… That’s 8AWG btw.

My finger that was a few cm away from got burns without touching anything.

And the craziest part was the “brightness level” of such a short. It was a very short white flash, but looking directly into a MIG/TIG weld is nothing at all compared to how bright this was.

After a little cleanup I attached the terminal connector without issues (now without skipping the kapton tape…).

The battery wires are run under the deck inside a channel in the aluminium chassis. The wires have protective braid around them and the deck was routed out to allow for more height for the wires, as the channel in the alu wasn’t deep enough to fit the wires. I did this with a dremel converted into a router with a 3d printed attachment, so it was a rather painful process, but the result doesn’t look too bad.

Then also made the hole around the trucks where the cables come up.

Now lets talk charge port. I chose the XT60E-F, as it can handle high amps (the pack and the BMS itself can handle a lot, wanted to have a charge port that can keep up with a fast charger incase Hendrik upgrades from the 18S Radium charger). Furthermore it’s nice to mount and has a protective cover which actually stays on while riding.

With a custom mounting 3D printed mounting block on the back which holds the nuts.

xt60ef mount.step (165.1 KB)

Then the pack got heat shrinked, the panel mount XT60E-F got installed in the enclosure, and the middle was done at this point.

Then came the painful wire management inside the ESC boxes: the stuff just didn’t fit. So I designed a riser for the ESC box:

I traced out the original walls on a piece of paper, took measurements, then transferred it into CAD. It turned out quite good fitment. The holes do need to be drilled out to 4mm because it’s 4mm dia in CAD, didn’t account for tolerance. My printer is shit at accurate holes anyways. 6mm height but turns out we needed more so there’s multiple pieces stacked on each other. I don’t like to make wiring too tight and then clamping down on it, I rather give it enough space. There was absolutely no chance of putting an XT90 Y splitter in the box stock.

escbox riser.step (154.3 KB)

After that we had some difficulties with VESC tool but with some support from Artem we managed to finish everything.

So here’s the functional version where I handed it back to Hendrik:

10 Likes

You are such a legend :clap:
Thanks for adding this and again learned something about my board and its history. Beautiful job mate and glad nothing more serious happened!

5 Likes

Where do you live?

And what board do you use to run to the corner store?

Jesus christ why are you soldering hot wires on such a pack!? :see_no_evil_monkey:

glad alls well that ends well!

4 Likes