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Street legal KZ440 cafe racer build

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buildsix:
Hi everyone

I just joined the forum today after checking out some of the other posts.

I started building an EV conversion recently using a 1981 KZ440 LTD cafe racer as a donor and have made some decent progress over the last few weeks. The drive system is now together and on the bench and I’m about to start the 12v wiring and the battery box fabrication. Just wanted to share what I’ve done so far as I’ve gone through a bit of pain in some areas and it may help other builders, plus I’ll have more questions so hoping to tap into some knowledge.

Overview for the conversion:
-1981 kz440 ltd with ktm duke 390 front end
-Custom adapted duke 390 brakes
-17” 8kw QS hub motor driven by a Kelly Controller
-24s NMC lipo pack @ 7.4kWh
-Thunderstruck tsm2500 charger with dilithium MCU, BMS and SOC meter
-Vicor 400W switch mode dc-dc converter
-8Ah antigravity 12v battery
-Motogadget mo.unit blue
-Motogadget motoscope pro

EST weight at ~140kg





I also put some videos together for the build if anyone is interested in checking them out. I ended up doing something a bit different with the drivetrain power so it may be of interest to some. The videos are a bit cringy as it’s my first attempt at anything like this so excuse the bad acting and terrible voiceover :D

TheRan:
Mate, that was very enjoyable to watch, don't know why you were selling yourself short. Usually the mention of cafe racer alone puts me off but that's because most of them are very poorly done, but your quality of work and the thought and effort put into it is very impressive and far beyond what I was expecting. I've subscribed because I'm really interested in seeing the rest of your work and this thing completed.

buildsix:

--- Quote from: TheRan on May 05, 2024, 05:18:49 PM ---Mate, that was very enjoyable to watch, don't know why you were selling yourself short. Usually the mention of cafe racer alone puts me off but that's because most of them are very poorly done, but your quality of work and the thought and effort put into it is very impressive and far beyond what I was expecting. I've subscribed because I'm really interested in seeing the rest of your work and this thing completed.

--- End quote ---

Thanks for the kind words and the sub! Glad you enjoyed the videos too, they are a lot of fun to make - and hopefully also help others doing similar projects. Really looking forward to getting this thing together to start road testing.

TheRan:
Honestly, with the quality of the video production and the way you present I would never have thought you'd only been doing this a few months and had 30 odd subscribers. Hopefully that number goes up steadily, with the effort you put in you deserve it and more people should see it. I'm glad you're going through the effort to get it road legal too so it can really be enjoyed.

buildsix:

--- Quote from: TheRan on May 05, 2024, 06:09:20 PM ---Honestly, with the quality of the video production and the way you present I would never have thought you'd only been doing this a few months and had 30 odd subscribers. Hopefully that number goes up steadily, with the effort you put in you deserve it and more people should see it. I'm glad you're going through the effort to get it road legal too so it can really be enjoyed.

--- End quote ---

Thanks again, that's really motivating RE the videos. A road legal EV conversion is something i'd been wanting to do for years and finally decided to try it since the cost of suitable batteries is now workable.

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