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The plan is to remove as little material as possible. Once the battery arrives I'll carefully fit it to the bike. I want to avoid welding on the aluminum chassis. My fear is the welding will change the heat treatment and soften the aluminum.

Thank you Don for all the wonderful information. Now I have to figure out how to get the most power and range into the fairly small space I have to work with. It is going to take some creative fabrication. Looks like I'll need to reduce the size of the shock tower cross member and the wishbone...

Thank you Don for all of this great information. I'll digest this and write a battery build specification for the bike I'm building.

The battery in the photo may have come from Eon: https://eonlithium.com/product/eon-max-range-72v-55ah-battery/

Found the 3D CAD for the V3 70H and 90H on grabcad.com

I stripped the chassis down to the needed components. Next comes the measurement process. I plan to CNC cut some full sized foam mockups for the motor and battery case. Does anyone have a 3D CAD model or CAD drawings for the QS138 V3 motor?

Please give me a ring when you are free. 760 822 7344 Dave

Are you atte ding the EMX World Championship this coming weekend? https://www.emxwc.com/

Hello Bob, Thank you for your message. I'd love to pick your brain before jumping too far into my 2011 CRFE build. We are going to call this the Frankencycle project. Please call, text or email me when you have time to chat. Dave Daum 760 822 7344 dave.daum@gmail.com

Hello Guys, I absolutely love the performance you are achieving with the CRFE! Today I purchased a 2011 CRF 250F. Photos and specs for the Bob Casper CRFE build would be greatly appreciated. I'd love to learn from the Don Cox/Bob Casper inventory of firsthand experiences. -- Dave