Puch/Sachs/Batavus Encapsulated Hall Sensor for Under Flywheel + Home Etched Boards

This is a rough mockup of what I'm thinking I'll do for a hall mounting solution for a CEV stator/flywheel. The design utilizes the mounting point for the mechanical points which are no longer needed.


The working part will be cast out of urethane with an encapsulated hall sensor within several millimeters of the magnets in the flywheel.

Top view of encapsulation showing footprint of 3D printed dummy/mold negative.

Sensor lead will protrude through the nub and out the stator through an existing hole. (3D printed dummy/mold negative)

Casting is perfectly sized to lock an M3 nut through old points threaded hole. Uses pivot point of the points to fix orientation.

Hall sensor -> 3.5mm audio 3 pole used for the trinket ignition from this post: http://deadped.blogspot.com/2014/03/trinket-arduino-dynamic-timing-video.html

Casting was a success!

The main thing I've been working on though is perfecting a process to etch my own double sided boards at home. I've had pretty good results and been able to use .12" traces, get them to effectively transfer and be continuous once etched. Right now I'm waiting on PCB drills so I can connect traces when they change sides. The bits I had didn't last very long, so I've got a set of carbide PCB bits on the way. Home etching for 32TQFP packages is doable! Biggest thing I had to do was increase the pad sizes for through hole transfers. Because of that, I'm likely going to have to eliminate the ISP header traces from the production boards.

Trinket Arduino Dynamic Timing Video + Spring Break Update

So, first, the video you've all been wanting to seeeeeeee... the DYNAMIC DIGITAL IGNITION video!!! huzzah! Sexy curves in action:

monitoring the switching pin on the microcontroller to make sure it isn't going to be fried.

board prototype idea

This happened the day before I left for spring break and was glorious. Spring break packin:

I'm working on making this ignition more physically robust and perhaps making a debut of it at Inverness. I still have a little to do moped wise though and a lot to do car wise. Old Yeller has to be gone through entirely for road worthiness as the 2 inch hitch on that car could likely haul both bikes. If it can't, I may be inclined to take brownie since I know his service record better and he has many "new" parts. Brownie needs the new sport exhaust package installed from IPD though, so that has to happen tomorrow if it ever shows up. I'd have to throw a bike on the roof though, and that coupled with is 4 speed transmission = terrible gas mileage.

Spring break wrenching 2014 first up was the maxi. I'll get some new pics of it posted some time before I leave maybe, but I added some chrome trim to the frame and it is CLASSY. Wiring is cleaned up, painted and detailed flywheel and finished up all the little stuff (like shortening the speedo cable). This bike is done for a while till it gets a reed kit. ZA50 geared at 21x37 and has so far been GPS'd at 51mph with all stock parts.

Next up was the derbi. Lots to do to this little guy. I made a puller for the clutch... hardware was $3 total. Had the parts lying around since last time I was home ;) Then I raised the exhaust port a little and resealed the engine (no leaks, knocks on wood). Thought I needed new crank seals but turns out pre-mix was just running down the electrical into the stator (no airfilter) sweet. For some reason, the condenser all the sudden quit working though - like instantly. I was out riding and got a GPS speed of 41 out of it and then it started backfiring. Points arced like a beast, so I did a condenser and all was well. Nothing changed timing wise it just up and quit. Weird/LAME. Can't wait to put digital ignition systems on all my bikes. I also made a CVT cover because the thing throws junk ALL over the frame. GPS speed of 41 was with lots of airleaks, so I'm leaning it out now that it's sealed up.

The weather in Inverness will be glorious. I can't wait. High today was like 40 and last night it was flurrying.

Adafruit Trinket Ignition Static Timing Test + Pre-Inverness To-DO List

Here's a quick video of the bike running on a trinket controlled digital ignition. Static timing still needs to be verified and ignition needs to be calibrated, before messing with dynamic timing, but it runs and revs out. Rode it around the block before I had to put it away. Spring break is next week, so expect lots more updates.

My static code is pretty simple, sweet and short:

On the to-do list before inverness:

• make adapter to mount homoet 6p to vespa or derbi for inverness
• rebuild the puchonda engine with the manual transmission
• tidy and pretty up the maxi
• fix the transmission in the general
• modify the 2" rack on Old Yeller to accept two mopeds
• make mounts for putting mopeds on the thule rain rail mounted rack
• make sure no more of my exhaust on Brownie is going to fall off
• last and foremost, get the trinket ignition off the SLA and running off of the vespa electrical