solar-e-bike-Derek
New Member
- Joined
- Jan 23, 2022
- Messages
- 11
So glad to find this forum after doing lots of scrolling and searching online. I'm working on a new project (keep scrolling below to see my specific challenges / questions) to replace my solar bike camping trailer I initially built two years ago. That original version was slapped together fairly quickly with the basic elements being:
* Chariot Cougar 2 Bike Trailer (I found it used, which made it affordable)
* RichSolar 80W Panel
* Jackery 240 Solar Charger / Battery (I've since upgraded to Jackery 300 and have both of these still)
* Kamprite Tentcot
Since the Tentcot is so bulky I had to create a roof rack to carry that and provide the surface for the solar panel. I built the rack almost completely with aluminum crutches from the thrift store. I mounted the panel to the carry bag for the Kamprite and built a little corroplast substructure inside the bag to hold it and threaded the wire through and out so it could reach the Jackery inside the trailer. Also sewed a strap onto it to hold it to the roof rack. I'm actually planning to sell this whole set-up once I've finished my new trailer to recoup some of the costs of the new one. I haven't put a price on it yet but it would reflect the prices I paid for the components and a big discount since it's all used now. I might keep both for the summer if I find someone who wants to try it out and go for a camping trip with me. (I live in Seattle and you would need to rent or own your e-bike, I don't have a spare bike). The trailer itself has not been permanently altered, the roof rack comes off really easy and is a great little child hauler / utility trailer.
This is all pulled by a Bosch Power Train e-bike with lots of torque to get me up the hills and I've never found one that a combo of muscle and motor cannot conquer. The only problem is, those hills kill the battery and so I was trying to figure out a way to power my rides for more distance, which is what spurred the first version of trailer. I carry all of the typical camping gear you would expect. It's not minimalist backpacker style, and I like to enjoy some comforts once I get to camp like a comfortable chair, a nice cooking stove, and the Kamprite allowed me to set up a tent in like 1 minute.
It's now time for Trailer 2.0 and the planned improvements include:
* Narrower design (Chariot Cougar 1 Bike Trailer Chassis I found online)
* More aerodynamic (with a longer, boat-like shape and no roof rack - swapping Kamprite for a light, compact camp tent)
* 2X solar capacity (160W)
* 2X+ battery capacity (640 Wh)
* Faster charging with new MPPT controller
* Easily tilt the "lid" open for optimal charging angle (maybe even while moving)
* Completely water tight (Fiberglass) body and secure lockable closure
Challenges / Questions I've got:
* How do I build a robust battery system that can withstand bumps and vibrations?
* Could I keep my Jackery as back-up system and to avoid installing stand-alone power inverter and "feed" it from the MPPT as the "load"? Also nice to be able to bring your battery into the tent a night to run a fan or something, Jackery could do this.
* How do I build the "lid" to be water-tight and have the ability to "open" at multiple angles to optimize charging. Lid would not be open when raining so does not need to do both simultaneously.
* I've never worked with Fiberglass before - I would love advice on fabricating.
* Trailer will be longer and need to make sure I'm arranging the wheels so that there it not too much weight behind the wheels (for stability)
Sidebar: Just bought a SunPower 100 panel and I think it's counterfeit. Purchased on Amazon from seller Expert Power. Anyone else running into counterfeit panels out there? It works, just not how I expect SunPower to work, so I feel like it's a cheaper panel that's been slapped with the SunPower logo to get a higher price. Logo looks a little off and does not match the SunPower 50 I bought last year. I'm sending the SunPower 100 back and buying the SunPower 110 which hopefully delivers a similar level of performance against the rating I get from the SunPower 50. You can see in the rendering I'm planning on having the 110 and 50 on the top of my new trailer. Update: Seller sent me a paid return label so they've done the right thing, but I wonder how many other sellers are pushing this "not SunPower" panel? The 110 is a lot more expensive ($245) but probably the real deal and so I'm biting the bullet. This seller is calling the 100 "discontinued" and selling it for $130, and that just sounds too good to be true, it was $179 on Amazon. https://www.zampsolar.com/products/sunpower-100-watt-flexi-solar-panel#:~:text=Zamp Solar Discontinued Solar Panels,are available in limited quantities.&text=The panel is thin but,output due to micro cracking.
* Chariot Cougar 2 Bike Trailer (I found it used, which made it affordable)
* RichSolar 80W Panel
* Jackery 240 Solar Charger / Battery (I've since upgraded to Jackery 300 and have both of these still)
* Kamprite Tentcot
Since the Tentcot is so bulky I had to create a roof rack to carry that and provide the surface for the solar panel. I built the rack almost completely with aluminum crutches from the thrift store. I mounted the panel to the carry bag for the Kamprite and built a little corroplast substructure inside the bag to hold it and threaded the wire through and out so it could reach the Jackery inside the trailer. Also sewed a strap onto it to hold it to the roof rack. I'm actually planning to sell this whole set-up once I've finished my new trailer to recoup some of the costs of the new one. I haven't put a price on it yet but it would reflect the prices I paid for the components and a big discount since it's all used now. I might keep both for the summer if I find someone who wants to try it out and go for a camping trip with me. (I live in Seattle and you would need to rent or own your e-bike, I don't have a spare bike). The trailer itself has not been permanently altered, the roof rack comes off really easy and is a great little child hauler / utility trailer.
This is all pulled by a Bosch Power Train e-bike with lots of torque to get me up the hills and I've never found one that a combo of muscle and motor cannot conquer. The only problem is, those hills kill the battery and so I was trying to figure out a way to power my rides for more distance, which is what spurred the first version of trailer. I carry all of the typical camping gear you would expect. It's not minimalist backpacker style, and I like to enjoy some comforts once I get to camp like a comfortable chair, a nice cooking stove, and the Kamprite allowed me to set up a tent in like 1 minute.
It's now time for Trailer 2.0 and the planned improvements include:
* Narrower design (Chariot Cougar 1 Bike Trailer Chassis I found online)
* More aerodynamic (with a longer, boat-like shape and no roof rack - swapping Kamprite for a light, compact camp tent)
* 2X solar capacity (160W)
* 2X+ battery capacity (640 Wh)
* Faster charging with new MPPT controller
* Easily tilt the "lid" open for optimal charging angle (maybe even while moving)
* Completely water tight (Fiberglass) body and secure lockable closure
Challenges / Questions I've got:
* How do I build a robust battery system that can withstand bumps and vibrations?
* Could I keep my Jackery as back-up system and to avoid installing stand-alone power inverter and "feed" it from the MPPT as the "load"? Also nice to be able to bring your battery into the tent a night to run a fan or something, Jackery could do this.
* How do I build the "lid" to be water-tight and have the ability to "open" at multiple angles to optimize charging. Lid would not be open when raining so does not need to do both simultaneously.
* I've never worked with Fiberglass before - I would love advice on fabricating.
* Trailer will be longer and need to make sure I'm arranging the wheels so that there it not too much weight behind the wheels (for stability)
Sidebar: Just bought a SunPower 100 panel and I think it's counterfeit. Purchased on Amazon from seller Expert Power. Anyone else running into counterfeit panels out there? It works, just not how I expect SunPower to work, so I feel like it's a cheaper panel that's been slapped with the SunPower logo to get a higher price. Logo looks a little off and does not match the SunPower 50 I bought last year. I'm sending the SunPower 100 back and buying the SunPower 110 which hopefully delivers a similar level of performance against the rating I get from the SunPower 50. You can see in the rendering I'm planning on having the 110 and 50 on the top of my new trailer. Update: Seller sent me a paid return label so they've done the right thing, but I wonder how many other sellers are pushing this "not SunPower" panel? The 110 is a lot more expensive ($245) but probably the real deal and so I'm biting the bullet. This seller is calling the 100 "discontinued" and selling it for $130, and that just sounds too good to be true, it was $179 on Amazon. https://www.zampsolar.com/products/sunpower-100-watt-flexi-solar-panel#:~:text=Zamp Solar Discontinued Solar Panels,are available in limited quantities.&text=The panel is thin but,output due to micro cracking.
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