Mr_o_uk’s Mildly Modded Metruck

[mr_o_uk]

This speedo mount is starting to annoy me. Thought i was there in terms of design. Has taken about 8 iterations to get it right. So one last print and it failed 2 hours from the end.

Close enough to give it a try.

Someone more print and hopefully that’s a job ticked off.

At the same time I tried the push button spacers. Gives a little more room for the wires in the neck but doesn’t look as good.

Have found some short / 90degree buttons for the momentary self reset ones, but struggling to find some for the latching ones. Need to find a good short button if anyone has any suggestions?

I also sent off my battery tray to my local laser cutter guy last night to get a price on that.

[mr_o_uk]

Ok, print went ok, although I have to get the finish a bit better at some point. I used threaded inserts this time (first time I’ve used them) and seems to work well…

[mr_o_uk]

Have found someone to rebuild my battery. Wattico. Will add contact details here for others if it goes well.

I’m gonna use the original battery and work round that rather than a new battery. I can’t fit anything much bigger in because of the mount.

In the meantime, I have been tidying the wiring (I lengthened a bunch of wires so that half could go up the left of the neck, and half up the right.

I lengthened some of the button wires to make it easier to route cables.

I still can’t find a permanent 12v fees for the ignition. You only seem to get a 12v after the ignition is turned on.

I changed my button bevels slightly and reprinted them.

I’ve ordered fuel tank straps to mount the battery in the short term - tip I get a tray made up - as my old laser cutter contact has gone quiet.

I’ve made a box for the cable signal converter so the wires don’t get tangled with the throttle cable.

Think that’s about it. Just still waiting on the battery - and then I’m going to try and shave down the plastic floorboard and space it.

[mr_o_uk]

Waiting on my battery still, it couldn’t be revived so needs a full rebuild. Which isn’t cheap.

In the mean time I have been working on a rear number plate mount. Hugger style like my other bikes, but this time I’m going to try and make touting 3d printed brackets and carbon fibre rods. First design was way off. So got no decent photos to show it yet.

Have also started filling out the paperwork to let the DVLA know the bike is now electric. That can take months 2)3! Sent off and. I need an MoT before I can send it off. You need to provide photos and evidence of the build. So was a good job I created this page!

[mr_o_uk]

Attempt number 8 and the bracket that bolts to the case is about there…

Have got 10mm carbon fibre rods. So just printing attempt number 2 on the bracket at the other end. Not sure if it’s going to be strong enough though. May have to start researching carbon fibre filament.

[mr_o_uk]

Need to rotate it by about 10degrees to bring it up. And need to shorten the carbon fibre rods so it sits closer to the tyre but it’s getting there…

[mr_o_uk]

Still waiting on battery, but in the meantime have sorted a kickstand.

There was a thickening on the bottom of the case where a rubber mount was fitted for the central kickstand to raise up against.

So I bought a few kickstands off eBay. They all seem to be 38mm spacing on the bolts so drilled and tapped some m5 holes and fitted a kickstand…

[mr_o_uk]

Have also done a version 2 of the rear hugger style number plate.

Rotated the arms up. Put a curve on it. Put holes for the light cable to run through the middle of it and the tubes. Put more of a drop on the case bracket to add to the lever arm. Added holes for m4 Allen cap head bolts through the carbon tubes to stop it rotating. Printed it solid.

Feels pretty solid. And I quite like the design.

[mr_o_uk]

Thought I would have a go at a rear fender.

Not in the mood to make a 3d printed mount this time, so I decided to use the old fender as the basis for the mount.

I cut it down to keep the connection.

Have an R1 bracket lying around so going to bolt that to the cut down part.

Need to print some angled spacers.

[mr_o_uk]

Swapped to a different r1 fender that had symmetrical mounting points. Created an adaptor plate as the fixings were offset to to the old fender due to the wheel being bigger…

Looks ok, but it’s cheap and rubbish quality. I have epoxied the weak points. Let’s see how long it lasts…

Only regret is I wish I hadn’t cut the original fender for the other fender I had. If I had left a bit more on the side bolt I could have fixed the fender to it on the side and it would have been much sturdier.

One day I’ll scan it and do a proper mount.

[mr_o_uk]

I tried converting the 72v to 12v for the ignition feed, but it just cycles on and off as there is only one live on at each time.

So I think o need to get rid of the relays and original met key. And put in the ecooter key.

So that means getting the Honda shear bolts off first. Fun. Then designing a new key guard to fit. So if anyone has a 3d model of it let me know!

[mr_o_uk]

I bought an under seat storage box to hide the controller etc.

I don’t really like the look of it. So may try and make something less obtrusive myself.

[mr_o_uk]

My final to do list…

[mr_o_uk]

I’ve got a new working battery back.

It’s only small but will see how many miles I can get out of it. So first test ride will be this weekend hopefully.

Have started on fitting the ecooter key instead of the met one.

Had to grind a slot in the security screws to get them out.

The new ignition fits the bolt centres:

But it’s a bit shorter so I need to make my own key guard.

I’ve modelled the original one with a slight variation so will print that and see what needs adapting.

[mr_o_uk]

Need to trim the ends but have supported and strapped down the battery with aluminium fuel tank straps with a rubber c seal between.

Have always wanted the floor board in place. Have checked and it’s too high to pack up. So @CeCeBruse im using your method. Hopefully I’ll get this right as met parts are hard to come by in the UK!

So measured it up and going to cut out this section to start!

And a test fit…

Doesn’t look to bad. I’ll have to find some way of covering the battery with a formed plastic housing 1 someone will make a bespoke one I’m sure. Then it will look a bit like the Yamaha giggle floorboard.

I think it’s will end up ok.

The bike is running and pretty much there. Just need to sort all the plastics.

And get the bike on the ground - I didn’t think about that when I was building it on the table. It’s the wrong orientation to use a ramp. So might have to find 3 other people to help me lift it down? Is 4 people the right amount to lift it??

[mr_o_uk]

I’m pretty much done, other than sorting the plastics and key angle out.

Borrowed a hoist to get it down from the bench.

First time seeing the other side!

Test rode it just down the street. Is pretty fun. I’ll take a video tomorrow if the weather is ok.

[mr_o_uk]

Some more photos…

[mr_o_uk]

Quick video here:

- YouTube

The noise when moving is the number plate bolts catching on the tyre. Have cut them down since.

[CeCeBruse]

Man, seeing this thing finally roll off the stand under its own power. That’s huge! After all the months of work you’ve put into this build, watching it move on its own is just incredible.

I’ve been following along with every update, and the way you’ve put this whole project together has been seriously inspiring. The attention to detail, the problem-solving its all paying off now.

Honestly, Ive been dreaming about doing my own EV MetRuck build someday. The only thing holding me back is that getting access to the parts here in the U.S. Also been watting to see someone use this motor with the swingarm set up like this for awhile. The guy in China that sells them will not give any info on it at all. But watching what you’ve accomplished this makes me want to figure it out anyway.

Now I’m just waiting for the next video, where you actually take it out for a ride and report back. I cant wait to hear how it handle? What’s the power delivery like? Does it live up to everything you hoped it would be? What your top speed and range is like.

Can’t wait to see what’s next. Keep those updates coming!

[mr_o_uk]

Thanks @CeCeBruse. It’s been fun to do. Partly did it to see if I could. And I couldn’t have done it without a 3d printer that’s for sure - it’s opened up modification for me.

I can’t take it on a long ride yet as I need to get it re registered with the DVLA as electric. Just working through the paperwork and process at the moment.

I think it’s

1. Get an MoT.
2. get a letter from a garage saying they confirm it’s electric.
3. Fill out a v627/3 form.
4. Compile a document of supporting evidence (photos and statements.
5. Send all of the above with the V5c to the DVLA.
6. Wait for someone to come and inspect it.
7. Wait for a new v5c.
8. Ride!!

So it’s not straight forward. But once I get through all that I’ll do some ride videos with my helmet cam.