Inside the floor

This is the wiring for the Power Assist. At the left, you can see how the wire was routed above the rectangular cutout in the rear bulkhead through which the chain must pass. At top center you can see the battery cutoff switch. The terminal block on the right incorporates a 30 amp fuse, and the four battery connectors, wired in parallel.







Foam is cut to fill the void in the floor, and isolate the battery packs from each other, and from the structure of the bike.

I also used a couple strips of coroplast to keep things tidy and out of harms way. The open section to the right of center is where the chain will pass through. The electrical tape was just to hold things together till ready for final assembly. I plan on attaching the batteries to the floor with velcro, and using spray adhesive on the foam to hold it in place. I don't want to mount the foam permanently till the holes in the U-channels for the floor plate have been drilled, so that I don't have alot of aluminum debris stuck down there.

Getting the cockpit sideplates on was rather challenging. I didn't trust myself to prebend them, so I had to force them around the wheelwell and rear bulkhead, drilling and applying clecos as I went. Taking pictures during the process was very impractical since I got so involved in the struggle to conform the flat sheets of aluminum into graceful curves.

Of course everything had to be disassembled to remove chips and deburr all the holes. Then clecoed back in place again, and finally riveted. I had to drill out some rivets in the rear of the one cockpit side plate to get the tail section on, but that's a tale for another time.