Rebuilding Terry Hershner's Streamliner Pt. 2
Page updated Sep 20, 2014
The batteries were tucked in tight but Terry's seat was too high
We had a problem: After two weeks of work, Terry was still sitting almost as high as he was before. This was because we had gone to great efforts to keep his rear batteries within the 24" width of the front streamlining. But the nose was no longer 24" wide...

Terry's nose was now 28" wide because he had stuffed 9 chargers up there!
This turned out to work to our advantage since the tail could now be 28" wide, too. If the batteries could be located outside the swing arm, they could be mounted much lower. The seating could be lower now, too.

All that work for nothing! Reluctantly, we started over to build a new tail structure.

Terry carries 9 chargers
Terry's willingness to carry so many chargers allows him to charge fast.
When he charges, Terry consumes four automobiles worth of power! Four J1772 nozzles at once! Even tho, it still takes 45 minutes to fully charge. But then he can go 125-150 miles at 70-75 mph.

No electric motorcycle in the world can do this. Terry Hershner is a true pioneer.

Chargers are heavy. But if you want to charge fast, you have to have lots of them. Each charger weighs about 20 pounds which means that Terry is carrying 180 pounds of chargers!

The best place to keep the weight is up front, which is why Terry had to spread the fairing out.

Back to designing a new tail structure

Terry has 5 batteries* totaling 18kW hours of power. Three (integrated) batteries are already mounted inside the frame up front. We need to mount the other two at the rear. Because the nose is wider, the tail can be wider to match. Now, we can mount the batteries lower and wider.

*He has one more 3kW hour battery he can add for record rides.

Basically, what we are doing is building a big box around the rear of the Zero to hold the batteries. Each one weighs around 60 pounds. Once this structure is solid, we will add the seat, floorboards, seatback bulkhead and the tail.

As you would expect, the entire rear section comes off with 3 bolts, just like the nose.

Terry likes this much better. I do too. The rear shock has been removed and the tire is in its "All the way up" position. The up position determines the lowest position Terry can sit.
Terry sitting, batteries in place, Zak bouncing and Alan measuring.

We are trying to figure out the lowest the tail can be and not drag in road dips - like when leaving an angled driveway.

The Seat bulkhead provides the beginning of the new tail.

I am making the strongest, lightest space frame possible out of tetrahedrons. The next step is to wrap it with milk carton paper to make a slippery shape that helps the air slip by.

July 1, 2014: Ready to be covered
Meanwhile, Terry is figuring out how to mount 9 chargers up front.
This is what is inside a charger. 110 v plug in on the right... 72 v DC out on the left.

Terry has ten of these mounted at the front of his Zero. That is about 200 pounds of chargers.

With the aluminum structure in place, I could see that big areas of Terry's streamlined bodywork would be flat. "Flat" is best handled with Coroplast. We got two big sheets of 4mm. For expediency, we assembled the skin with Banana Tacks and aluminum foil tape. Nashua brand. Great stuff. Those rectangular batteries certainly dominate the design of this thing. Look at how they stick out at the bottom.

The tail is now very easy to make because of the seatbulkhead. Once the bulkhead is in place, trimmed at the bottom to fit the rider... in this case, Terry, the rest of the tail "falls into place". Notice the round pad behind Terry's helmet to keep it from clanging on speed bumps.

Check out how perfectly his new backrest fits. Because he sits about a half a foot lower than before, Terry had to cut his windshield way down, too.

July 2, 2014: Terry Hershner and his mighty Streamlined Zero ZF-18.

Ready to set new electric records

Postscript dated July 15, 2014: Terry never left California. Sitting on a bare metal seat pan instead of cushions, he rode his Mighty ZF-18 anyway, jamming his back. That was the end of his cross country riding for a while. We missed him but he was able to make his presentation at Vintage Days via SKYPE:

SKYPE-ing was Diesel Fred Hayes' idea. Professor Richard Goff, left, Alan Smith and Diesel Fred helped Terry with his presentation.

Get well Terry. We all missed you.

Rebuilding Terry's Streamliner Pt. 1

Rebuilding Terry's Streamliner Pt. 3

Master Index to the Last Vetter Fairing Story

Updated Sep 20, 2014

Posted June 21, 2014