Fuel filler / Charge port
Updated: Jun 9, 2019
I took some measurements and started designing (SketchUp, again) a replacement fuel filler neck & cap. At first I thought I'd use the same Anderson connector as was on the batteries I intended to build (and have since completed). I can't, right now, remember why but I changed my mind and used the XLR 4-pin socket to match the plug that arrived with the charger... the same sockets in fact as I fitted to the two batteries for charging - keeps the parts list simple ;)
During first fit though, I decided to change the design (again) to an 3pin IEC mains 110/220V AC socket - as per the mains cable between the wall outlet and the charger input. This was mostly because, having a drink at the bar, discussing charging one night, we all agreed that the charger would always be required to charge the scoot (obviously). My idea was that the charger should be carried in a back-pack / ruck-sack or, if space wasn't too important, under the seat ! It was pointed out to me that the charger would then need to be connected to both an available wall outlet and the charge socket, behind the seat. Seemed pretty obvious to me... what wasn't so obvious was that everyone agreed it would be simpler just to connect the bike to the wall socket - no charger to play about with or fall off the seat (or wherever else it had been balanced) and break. Seems reasonable ! In addition the space under the seat (on this scoot) is pretty poor anyways (I think I've already mentioned that somewhere along the line...) so... why not use it for the charger ? ? ? As a bonus, the charger is always dry under the seat - it wouldn't necessarily be so, balanced on the seat / next to the scoot during charing...So... why not indeed ? !
And, as it transpires, there's still some space left over for documents and gloves etc...
The 'downside' to this approach is that the scoot will have a fixed / permanent mains AC item wired in at all times and although it won't (obviously) be live at all times, I'm unsure as to any safety regulations with this approach. Having said that, the IEC connector could always be swapped out for the XLR connector in around 10 minutes... so... What's not to like with this approach ?
The final connector, fitted on the scoot with the fairings back in place, looks like this :
The design incorporates an 'O' ring on the lid / cap and a large overhang to reduce the chances of water ingress. It has two large drain slots built in (semi-circular, forward and aft of the raised, central, IEC socket, to prevent water build-up if any gets in.
The mains cables (L, N & Earth) are soldered and heatshrunk before being liquid silicone sealed. The cable terminates in the under-seat area with the original IEC plug for the charger. The charger output (XLR connector) connects to the, now redundant, original XLR socket thereby keeping it all fully removable for service etc...
A little smear of silicon grease on the 'O' ring and the lid / cap is a simple friction twist fit !