Teslanv's Simple Stainless Steel Battery Enclosure

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teslanv   100 MW

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Location: Bellevue, WA - USA
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Teslanv's Simple Stainless Steel Battery Enclosure

Post by teslanv » Apr 06 2017 12:25pm

I developed a very simple design for a rectangular Battery Enclosure. The Dimensions can easily be customized to fit any desired Internal Height/Width/Depth. This design allows for mounting to your bicycle's Water Bottle bosses with extra holes for longitudinal (front to back) adjustment in the triangle, at 16mm increments. (Holes are spaced 32mm on center, with a 8mm offset from center, so you can just swap the base plate 180 degrees for the last 16mm of adjustment.)

Here are three DXF Files for either a single 6S-16AH Multistar or a Pair of 4S-16Ah Multistar batteries or either 3X4S or 2X6S - 10Ah Multistar Batteries.

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Please note that the CAD files are sized in INCHES (NOT METRIC)! To my dismay, BigBlueSaw requires imperial sizing, instead of the usual metric sizing. If your shop requires metric, you will need to scale these files up by 25.4 for millimeter sizing.

My DXF files here are free for personal use, as long as you don't reproduce them commercially. If you are not able to make modifications to these DXF files yourself, shoot me a PM, and I can modify for your needs. For CAD adjustments only, It would just be a $10 fee for my time to resize the CAD file to your your size specifications. I can also produce and ship you a kit of parts. You can specify either Min. Internal dimensions, or maximum external dimensions. Pricing for a kit would start at $150 (Smallish size) for one unit, with discounts for multiple kits. (Water-jet 304 Stainless is the bulk of this cost, particularly with small quantities.)

"Kit of parts" would include:
1/16" THK 304 Stainless Base & Upper Cover.
5mm RivNuts installed, and including 5mm Pan Head Stainless Screws.
1/2" Foam for Base Plate * 1/8" Foam installed in Upper Cover.
01 - CAD.JPG
01 - CAD.JPG (30.3 KiB) Viewed 812 times
02 - Waterjet Parts.jpg
02 - Waterjet Parts.jpg (39.75 KiB) Viewed 812 times
03 - Padding Added.jpg
03 - Padding Added.jpg (43.34 KiB) Viewed 812 times
04 - Perfect Fit.jpg
04 - Perfect Fit.jpg (81.86 KiB) Viewed 812 times
05 - Base Mounted.jpg
05 - Base Mounted.jpg (64.8 KiB) Viewed 812 times
06 - Padding in Base.jpg
06 - Padding in Base.jpg (69.55 KiB) Viewed 812 times
07 - Battery & Box Installed.jpg
07 - Battery & Box Installed.jpg (107.96 KiB) Viewed 812 times
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

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fechter   100 GW

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Joined: Dec 31 2006 3:23pm
Location: California Bay Area, USA

Re: Teslanv's Simple Stainless Steel Battery Enclosure

Post by fechter » Apr 06 2017 2:18pm

The metal box should also reduce the risk from fire if the pack decides to go off.
"One test is worth a thousand opinions"

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wineboyrider   100 MW

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Location: Tularosa, New Mexico
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Re: Teslanv's Simple Stainless Steel Battery Enclosure

Post by wineboyrider » Apr 06 2017 4:06pm

Intereting.
ES IS SAVED! THANK YOU JUSTIN.

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spinningmagnets   100 GW

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Joined: Dec 21 2007 10:27pm
Location: Ft Riley, NE Kansas

Re: Teslanv's Simple Stainless Steel Battery Enclosure

Post by spinningmagnets » Apr 06 2017 6:06pm

Well done! I have also used Big Blue Saw, and I have been happy every time.

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