Transplanting old internals into the new enclosure in few simple steps.

 

This enclosure version is available from Thingiverse - Thing: 4378914

You'll have to print and assemble it, with some carbon rods, like here.

 

Sanding and spraying

Learned this the hard way: all the cracks/glue spills/cavities that you leave, will show through the paint.

So, invest the time in the sanding. If necessary, fill the cavities with more epoxy and sand some more. It's worth it.

Took me an hour, in several sessions, while the kid was sleeping.

Final pass to 220grit:

sanded

Then go with light passes of the bedliner spray.

Overall I did 4-5 coats with drying in between

spray2
spray1

I'm still amazed with the quality of the coverage of this stuff, getting an almost professional look, even for a clumsy guy like myself.

Finished board
Finished board

Can't finish without comparison between the old and the new. Soon it will get the beautiful dirt layer of a working piece.

compare1

Swapping time

All the internals are coming from the old enclosure:

The donor and the new body
The donor and the new body

Gluing in voltage meter, the loop key harness, and the charger socket first.

Fun fact: it was easier to break the old enclosure around these than to wiggle them out.

20200518_000709

Once this is over, padding the bottom with foam and swapping the battery.

Make sure it doesn't move, wire all again and you're almost done

20200518_212015
20200518_220158

The next step is obvious, spend evenings on the floor tucking everything in and closing the thing:

floor

Then of course go riding:

20200524_132645

Enjoy,
Dani

 

Like what you read? Find it useful? Leave a comment and let me know, thank you.

 

Please subscribe so you won't miss future posts.

Know someone who might enjoy this? Forward this to a friend.

Follow me onĀ  Instagram for more frequent updates

As always, you can email me with any question dani@dosimplecarbon.com