The bike controller connectors that I’m currently using are modeled from the KU63 brand motor controllers that I purchased from EVAssemble.  I was mistaken when I first purchased this controller, thinking it was the KU63 discussed on Planet Sphere in regards to mods.  It turned out to be a similar controller.  However, it had the same connector types as the KU63.  I eventually did purchase the KU63 controllers from BMSBattery and was a bit put out by how small they were.  I assumed they were cheap spin offs and wouldn’t perform as well.  They performed better, I had a bit more speed and they offered everything the EVAssemble controller, I’ll name PS-CN24V240WBL.  I recently purchased another round of the KU63 controllers, but was shipped some other brand.  I’m not too upset about it, since these were $15 each and I would be modifying them anyway.

 

 

 

 

With all that said, I want to come back to the signal and low voltage connectors these controllers use.  At first glance I would think they are Molex connectors, but they are not.  These connectors are spin offs and I’ll need to replace them with sourced connectors if I plan to do any mods.  The only connectors that are on these controllers that I have been able to source are the JST-SM connectors from Grin Cycle in Vancouver, BC.  They fetch for roughly $12 for a bag of various connector pin counts.  I like the JST-SM connectors over the Molex only because of my lack of experience with the Molex in the field.  With that I will consider using the Molex, but will plan to use the JST-SM.

Putting all this together has caused me to make sketches of the components and get an idea how they would all fit.  It suddenly hit me that 3D modeling would be the logical next step in getting the casing right.  I’ve used Google’s SketchUp for large scale data cabling operations before.  It seemed to make perfect sense to use this for modeling a case.

I found some interesting offerings, of which DesignSpark PCB had the most appeal.  I didn’t need to build a working circuit board layout.  All I really need for this project is the ability to fit scaled boxes around and design the case around it.  With that, I’ll start the drawings using SketchUp.