jimw1960 wrote:I thought I might start a thread so we can show off our innovative methods for housing a battery on an ebike. I'll start with the one I just finished. The blue box on this bike is the battery housing I just finished building out of 63 mil aluminum sheet stock. It mounts to the water bottle cage bolts and is quite sturdy. Inside is a Ping 48v 20Ah and crystalyte controller. Paint job is blue metallic rustoleum rattle-can special with three layers of clearcoat. The black rack trunk used to hold the battery and controller but it was too top heavy and broke a weld on my rack. Now it is completely empty and is used for hauling groceries, loads of mulch for the garden, etc. The bike handles much better with the lower center of gravity.
Now let's see what y'all came up with.
Vim wrote:Nice work, Jim. How do you open it? Any pics of the inside with everything in it?
broloch wrote:jim, how much weight did you put on the rack to break it?
Zoot Katz wrote:Gotta love those pouch packs if they fit between your cranks.
Did you reconfigure it or did Ping build it to spec?
If the box is attached only at the bottle mounts, that's about 23 lbs more than I'd feel comfortable with them holding.
I strongly suggest adding a few clamps around the top tube to carry the weight. Use the bottle mounts primarily for stabilisation and security.
You have to sort your priorities damn quick while your batt box is sliding down the road and your down tube is collapsing after the mounts rip out.
www.recumbents.com wrote:I'm building a mount for my 20Ah 48V split ping pack to mount the batteries up by the head tube.
I'm building it from aluminum strap that is pop riveted together with steel pop rivets.
dnmun wrote:steel pop rivets are better. i never use aluminum rivets myself. make sure you use the proper length so you get good expansion on the outside of the joined layers, and tight seating of the material together. JB Weld and epoxy helps. but you have to assemble fast if you set up with epoxy to supplement the pop rivets, but it is strong as welded then too.
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