Convert AC/DC bike to ALL DC.

[New guy]

is there any quality for rewinding coil?
I want to install 60w/55w for my new CBZ Extreme in Dc.
how to identify the OEM and delhi made APE?

Go here http://www.xbhp.com/talkies/desi-bik...s-all-day.html

[ATHUL4R]

Go here http://www.xbhp.com/talkies/desi-bik...s-all-day.html

hmm it contains a little more info too thanks mate. dose any one tried in trivandrum?

[sajjt]

@ abhijeeth080808, rahuldevnath and sajjt,

Hi guys,

Im going for DC conversion of P150 UG3, but in addition to this I want to use
2 Auxiliary lamps (Autopal) with 2x100w(For Highways).

I want to source the power to headlight and two auxiliary lamps from battery.
But before that I want to make necessary arrangements to charge the
battery,to take the load of additional 200w.

So my queries are:

1) Can the rewinded coil produce enough watts to keep the battery charged.
If yes, I will be rewinding the coil myself, so i want to know how much
amount of 19guage wire is required to rewind the coil

2) Can the custom rr with some changes to the diodes take the load

3) Is there any other changes I need to do with regard to charging?

Waiting for the suggestions from the 3 Musketeers.

@ rahul you have a pm

So u want to light up 2X100W aux and going for DC conversion which will eventually end up with a HID of 35W min + another 15W for console, tail lights=250W roughly. Expecting too much from a puny alternator, I would say u've got 2 options:

Consider a 20AH battery which can be carried in a saddle bag or so

or

Ask nano's 500W alternator to meet this

Choice is urs.

Rewinded with 18/17G will give u a max of 10-12A which is approx 145W. So, if u can compromise with 2X55W aux + 35W HID then, go for coil rewinding with 18G and APE RR.

If you can get hold of a pair of good quality 55W aux lamps from Hella it can surely outperform the local assy with 100W.

And think of it before u go further, here sky is not the limit

[ATHUL4R]

you said it sajjt.

[Deepak Karanth]

@ sajjt

Thanks for the reply brother.

Oh, those two options made me realize what Im asking for from the puny coil .
Well its my fault though, expecting too much.

Now coming to the fact,

I had a spare 150 UG3 coil which catered out 35w for headlight.


Bought the 19G wire and went ahead rewinding (about approx 250-300gms) myself.

Result:

(hope you forgive the amateur job)

Coming to the Aux Lamps I wanna stick Autopal (Hella Out of Budget)
and 55w, as suggested by you(Ill switch OFF headlight while aux is ON)

Now I need to check whether my coil is producing enough juice (using multimeter) to keep all the things working.

Coming to the calculations:
2 Aux Lamps - 110w
Console and etc - 15w
i.e., 125w, which comes to approx 10A

So I need to get anything on the upper side of 10A to get things working, right.

And BTW can I use custom RR instead of Ape RR.

OT: How much does the starting range of Hella Cost?

[ATHUL4R]

the rough calculation of starting of hella from 1900rs+ (converted from $)
i think its a little expensive but the quality is good.

[Deepak Karanth]

the rough calculation of starting of hella from 1900rs+ (converted from $)
i think its a little expensive but the quality is good.

Thanks for the information Athul4R, will check the prices in JC Road and Update.

[ATHUL4R]

Thanks for the information Athul4R, will check the prices in JC Road and Update.

Welcome mate update the price with model no mate

[sajjt]

@ sajjt


Now I need to check whether my coil is producing enough juice (using multimeter) to keep all the things working.

Coming to the calculations:
2 Aux Lamps - 110w
Console and etc - 15w
i.e., 125w, which comes to approx 10A

So I need to get anything on the upper side of 10A to get things working, right.

And BTW can I use custom RR instead of Ape RR.

OT: How much does the starting range of Hella Cost?

Yes ideally u need to have a min charging rate of 10A for this setup on full load. But if u r going to use the aux lamps only on highways, 8A will do provided, u need to keep the rpms above 4K when using the aux.

There are RR designs u can assemble as a DIY, but APE is rugged and reliable for a two wheeler which is always exposed for water seepage and dust accumulation. U can consider applying epoxy layer to make the circuit water proof.

[Abhijeet Bhattacharjee]

@ Sajjt, my needs are arnd 7A as close to idling as possible.
1. What AWG do you recommend??
2. How much will the current increase when we rev the bike at say 6k RPM??? (Assuming stator's pumping 7A @ idling)
3. I have a puny 5A battery, do you think there's any risk if I run with so much current?

Thanks in advance

[Deepak Karanth]

Yes ideally u need to have a min charging rate of 10A for this setup on full load. But if u r going to use the aux lamps only on highways, 8A will do provided, u need to keep the rpms above 4K when using the aux.

There are RR designs u can assemble as a DIY, but APE is rugged and reliable for a two wheeler which is always exposed for water seepage and dust accumulation. U can consider applying epoxy layer to make the circuit water proof.

I tested the rewinded coil today.

There were positives as well as negatives.

The only Negative was Custom RR, don't know whats wrong but, output from
the RR terminals were 15v Min to 40v Max and 4A Min to 8A Max (excluding
the output at battery terminal mentioned below).
I was Like after seeing those readings.
I've double checked the connections and every components and connections are as per the bridge rectifier circuit(used by rahul and abhijeet).

Coming to the positives, stock vs rewinded coil results:
(excluding the output from custom rr terminal mentioned above)

Edit: (^MAX = 2000 to 5000rpm)

Now, what is the maximum Amps I can expect from my coil (I'm confused with the Amps at RR and at Battery), and what went wrong with regard to the RR

Please help.

[sajjt]

@ Sajjt, my needs are arnd 7A as close to idling as possible.
1. What AWG do you recommend??
2. How much will the current increase when we rev the bike at say 6k RPM??? (Assuming stator's pumping 7A @ idling)
3. I have a puny 5A battery, do you think there's any risk if I run with so much current?

Thanks in advance

Sorry I couldn't get u What is ur ride? Whats the present charging rate?

Coming to winding element gauge, its better to have the best possible thicker gauge again depends on the stator size. Am no expert in giving u a formula for this, as a rule of thumb u can take the first statement. But it will affect the engine performance if u load the stator too much AFAIK.

From the stock state, I assume we can go for a 50% boost by rewinding without affecting much to the engine.

If ur coil is capable of supplying the required current then, what makes a 5AH to suffer? To be on safer side, u can think of cutting off the loads on low rpms to safe guard. 7AH charging rate is no big deal for a 150CC mill, may be bit tough for a small CC ones as we had some experiences from some of the fellow members who tried the rewinding on 100CC bikes.

Multi pole stator coils are more robust in construction and performance as well. I guess this is why most of the manufacturers had chosen this over single core plates.

[ATHUL4R]

1)how much current consumed by LED strips? (strip with 12 bulb when we count when it glows)
2) " " " angel eye?

[Abhijeet Bhattacharjee]

I tested the rewinded coil today.

There were positives as well as negatives.

The only Negative was Custom RR, don't know whats wrong but, output from
the RR terminals were 15v Min to 40v Max and 4A Min to 8A Max (excluding
the output at battery terminal mentioned below).
I was Like after seeing those readings.
I've double checked the connections and every components and connections are as per the bridge rectifier circuit(used by rahul and abhijeet).

Coming to the positives, stock vs rewinded coil results:
(excluding the output from custom rr terminal mentioned above)

Edit: (^MAX = 2000 to 5000rpm)

Now, what is the maximum Amps I can expect from my coil (I'm confused with the Amps at RR and at Battery), and what went wrong with regard to the RR

Please help.

your custom RR does not have a voltage regulator. I think you have tapped the lighting wire from the stator output, tap it from after your bikes RR insted, that'll give you regulated output (arnd 18V max).

Sorry I couldn't get u What is ur ride? Whats the present charging rate?

Coming to winding element gauge, its better to have the best possible thicker gauge again depends on the stator size. Am no expert in giving u a formula for this, as a rule of thumb u can take the first statement. But it will affect the engine performance if u load the stator too much AFAIK.

From the stock state, I assume we can go for a 50% boost by rewinding without affecting much to the engine.

If ur coil is capable of supplying the required current then, what makes a 5AH to suffer? To be on safer side, u can think of cutting off the loads on low rpms to safe guard. 7AH charging rate is no big deal for a 150CC mill, may be bit tough for a small CC ones as we had some experiences from some of the fellow members who tried the rewinding on 100CC bikes.

Multi pole stator coils are more robust in construction and performance as well. I guess this is why most of the manufacturers had chosen this over single core plates.

ride is 07' Discover 135, has same electricals as UG3 Pulsars (except BCU) & and stator is same as UG3 Pulsars. Currently running an Avenger 180 stator with 55/60W H/L on AC. Battery charging Amps is 1.5A Max.
Want to convert to full DC, for that I need around 80W (~7A) at 2~2.5k RPM.
1. What AWG to be used???
2. Any ussues with overcharging or damage during long daytime rides???
3. Any other useful suggestions???

1)how much current consumed by LED strips? (strip with 12 bulb when we count when it glows)
2) " " " angel eye?

around 100mA

[ATHUL4R]

i saw some bike has lights in alloys? how to fix it and whats its cost?
is it need battery to work?