1. Make sure the wheels are chocked! Care must be designed into the vehicle to prevent rolling & runaway, since electrics have no compression braking.
2. Wear insulated gloves, safety glasses, steel-toed shoes, and old clothes.
3. Disconnect battery pack from electronics, both negative and positive leads when "off", parked, or serviced.
4. Never disconnect under load.
5. Discharge circuits through a resistor. For 120 volts or less, a 60 Watt, 120 volt light bulb in a rubber pigtail socket with insulated alligator clips should be fine. For more volts, double the bulbs in series or use a higher voltage bulb.
6. Insulate all metal on your tools except the very tip. Wrapping them in a couple of layers of electrical tape and/or dip in liquid plastic should do fine. Vacuum hoses come in various sizes that slide over some tools conveniently.
7. Consider Avcon charging units with handshaking for off board and on board charging.
8. Use ignition cutout switch on plug to prevent driveaway while plugged in.
9. Shield ALL exposed electronics from accidental touching with boxes or covers or clear plastic, or rubber, or tape.
10. No batteries near extreme heat of components.
11. No batteries near fumes or fumes near occupants or other fuels.
12. Brake logic, no braking while current is active in capacitors or motor.
13. Control wires & electronics must be on separate side to that of power cables to prevent RF interference.
14. No positive and negative loops.
15. Temperature measurement on motor and batteries.
16. Tachometer readings from motor.
17. Separate battery packs for emergency lights, headlights, keeping electronics alive.
18. E-meter, Zantex gives state of charge, amperes used, etc.
19. When fast charging battery pack, must water cool controller.
20. Have AC inverter onboard to run water pumps and auxiliary items.
21. If using chain, use chain guards, not chain case. Guard rear sprocket. Prevents locking up of gears.
22. Do not over spin motor or spin motor without load.
23. Forced motor cooling at low speed and current anticipation.
24. For first time drivers have valet mode and engine sound effects.
25. Valet mode battery management system.
26. Torque stabilization for motors need support attachment on front and rear to prevent damage when going over bumps.
27. Motor gear attachment use taper lock with compression screws.
28. Frame construction use chrome alloy 4130 aircraft quality, tig weld and pre-heat.
29. Design "Lift Point" on frame to remove large or heavy components.
30. Determine center of gravity (use 1.4 to 1 hypotenuse line).
31. Unitec welder three phase for welding battery tabs.
Connectors
1. Use Anderson connectors for connecting battery pack to electronics.
2. Have "pull fuse" or master breaker within easy reach of driver, marked for emergency personnel, and easy to operate.
3. Crimp connectors are much better than solder.
4. Use Teflon wires for all electronic connections and battery pack connections.
5. Consider special crimper (expensive) or AMP aircraft crimpier (or weld a 13mm hex socket & cable cutter).
6. Use thick walled connectors. No separate or split type (braised OK). Consider Zeus fasteners.
7. Perform a "Tug Test" at 70 percent on connections.
8. Bikes should have cutoff switches in seats, handle bars, and lanyard. Consider more.
9. Use DEM nuts for sheet metal.
Have ON-HAND in case of accident:
1. Emergency phone numbers, hospital locations, and exits.
2. Fire extinguishers approved for electrical fires.
3. A bucket of water to wash out your eyes and put your face into.
4. Boxes of baking soda to neutralize acid, chemicals, and as emergency fire suppressant.
5. Everyone can benefit from the eventual need to know medical conditions, blood type, allergies, eye and dental info, medications, and name of caregivers and doctors for each person easily available. You might as well keep this handy in cars, offices, workplace, and at home to speed treatment and help protect everyone with fast and correct information.
Miscellaneous
1. Use optical isolated commutation.
2. Do not use carbon fiber to house battery pack (unsafe).
3. Glue batteries to circuit board with aircraft tank glue. Try Sinco Sealant gun.
4. Throttle needs to be Magana three wire at 5K.
5. All wiring must be twisted to prevent RF interference.
6. Rubber cap all of the exposed connections.
7. Require a fuse on charger and vehicle.
8. Require full charge Avcon connector at 100 amps.
9. Require HID headlights.
10. Parking brake must LOCK with kickstand on bikes.
11. Require two contact switches. The extra protects in case of failure.
12. Wash your clothing right after you finish as you may get a few splashes of electrolyte on it.
More SAFETY TIPS.... 
Thanks to Bill Dube’, Ken Koch, Lee Hart, John Wood, Roland Wiench, Wayne Alexander, Roger Stockton, Victor Tikhonov, Chip Gribben, David Roden, NEDRA, Roderick Wilde, Wayland, Steven Ciciora, Derek Barger, Scot Colburn, Rich Rudman, Jim Husted, Electric Louie, James F. Jarrett, Jay, Robert, Randy, Uve, Father Time, Don, Otmar, pioneers, racers, and EV List members for training, guidelines, safety tips, and procedures.
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