Hidden rectifier / regulator
Posted: Mon Dec 02, 2013 10:48 pm
I was browsing Edit * BGM's * website, and saw that they sell a CDI unit hidden inside an old-style coil casing to give that "original" look. As I always run my scoots full DC with a Podtronics regulator /rectifier,I wondered if it would be possible to hide that away as well. So let's see shall we? -
Step 1, find an old-style rectifier and take it to pieces.

Step 2, take all the unwanted gubbins out, just leaving the original female bullet connector blocks in situ. This is midway through, those four coil mounting "lumps" have to go to leave a nice smooth surface to mount the Pod

Step 3, get your Podtronics and spend half a day shaving bits off until it all fits nicely inside the box then attach it. Cut down the four wires from the Pod very short (scarily short), solder them to the rear four sockets on the connector block and reassemble it all.

Step 4, put it all back together, including the metal mounting / heat dissipating block at the rear and there you go...

Step 5, Trial fit on frame, go for celebratory beer.

All you have to do then is modify the loom so that the relevant ends have original size bullet connectors, plug it in and off you go. Will it work? One possible problem could be overheating as the fins on the Pod are there to dissipate the heat to free air, not to the inside a plastic box. If that does happen, I'll get a Dremel and slice slots in the underneath and inside (hidden) faces of the box to allow some air circulation. If that fails, well as a last resort I can always cut the box cover down so that the connector block is still covered but the fins are exposed. As I have never felt a Pod unit in use, I don't know how much heat is produced so we'll just have to wait and see. But the answer to my question is...yes, it can de done.
Step 1, find an old-style rectifier and take it to pieces.

Step 2, take all the unwanted gubbins out, just leaving the original female bullet connector blocks in situ. This is midway through, those four coil mounting "lumps" have to go to leave a nice smooth surface to mount the Pod

Step 3, get your Podtronics and spend half a day shaving bits off until it all fits nicely inside the box then attach it. Cut down the four wires from the Pod very short (scarily short), solder them to the rear four sockets on the connector block and reassemble it all.

Step 4, put it all back together, including the metal mounting / heat dissipating block at the rear and there you go...

Step 5, Trial fit on frame, go for celebratory beer.

All you have to do then is modify the loom so that the relevant ends have original size bullet connectors, plug it in and off you go. Will it work? One possible problem could be overheating as the fins on the Pod are there to dissipate the heat to free air, not to the inside a plastic box. If that does happen, I'll get a Dremel and slice slots in the underneath and inside (hidden) faces of the box to allow some air circulation. If that fails, well as a last resort I can always cut the box cover down so that the connector block is still covered but the fins are exposed. As I have never felt a Pod unit in use, I don't know how much heat is produced so we'll just have to wait and see. But the answer to my question is...yes, it can de done.
