Image

Re-build of TW560, part one

I was very much looking forward to this part: Finally, TW560 is going to be put back together, as a Chimera of TW560’s main parts, TW524’s outer hull and TWxxx’s hood.

It will take time to get used to.

But I have really missed my TWIKE unlike any other possession I’ve had in my life. It’s a very strange and strong feeling.

I don’t know if other rare vehicle owners have similar feelings. It’s similar to how you might feel towards a very old and very dear friend.

Anyway: today is the day TW560 fights its way back to life…and it has also two of the most defining moments: does the frame fit and does the hood – from yet another TWIKE – fit also?

We start with TW524s Space Frame.

Fresh Luran frame

Fresh Luran frame


 
These views are very similar to the ones I saw when I visited Fine Mobile, The TWIKE Manufacturer. TWIKE frames and Luran hulls without any other parts afford views usually blocked from view.

A view one doesn't get to see too often

A view one doesn’t get to see too often


 

The first important moment comes when we marry the hull with a completely different hood. Every hood is slightly different as it is made and welded by hand. Minute differences have marked effects on the outer parts of the hood.

First fitting - looking good!

First fitting – looking good!


 
We’re lucky – the hood fits perfectly!

No need for any risky bending and coaxing to make it fit – whew!

This is one good-looking TWIKE!

This is one good looking TWIKE!


 
Next comes the moment I’ve been waiting for: the birth of TW560v2!

We take the main frame, complete with abrasions which we’ve not had to cover or repair and introduce it into the Space Frame. This step establishes TW560v2.

All those bad roads! Abrasion on chassis frame

All those bad roads! Abrasion on chassis frame


 
Andi’s plan is to create larger holes in the Luran hull which make sure there will be no abrasion anymore.

Larger holes to avoid abrasion

Larger holes to avoid abrasion


 
There is no immediate danger that the larger holes will have any negative impact structurally.

Larger holes to avoid abrasion

Larger holes to avoid abrasion


 
With this, we can add the large, characteristic, black battery bay at the back.

New TWIKE, battery bay has just been added

New TWIKE, battery bay has just been added


 
As this compartment protects the batteries from the elements, great care must be taken to make the enclosure as watertight as possible. This, historically, has been a problem for TW560. I’ve been left in the dark due to water entering the enclosure and killing a DCDC converter which died with a big POOOOF and lots of ionized air!

Battery bay, new clamps

Battery bay, new clamps


 
This will take a while to dry. The last thing which we can take care of today is the heat protection barrier above the motor.

A TWIKE motor can get quite hot – >90° surface temperature is not unheard of. This barrier protects the 1.5mm Luran plastic from this heat.

New heat protection

New heat protection


 
More to come! (as soon as the glue has set 🙂 )