Show Us Your Homemade Battery Housing

General Discussion about electric bicycles.
Spooky1   100 mW

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Re: Show Us Your Homemade Battery Housing

Post by Spooky1 » Apr 21 2013 3:05pm

Unfortunately the previous box was too small, I purchased the larger box from the same company, I think I prefer it tbh.
ImageUploadedByTapatalk1366574665.839967.jpg
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Tommy L   100 kW

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Re: Show Us Your Homemade Battery Housing

Post by Tommy L » Apr 22 2013 7:42am

Spooky1 wrote:Unfortunately the previous box was too small, I purchased the larger box from the same company, I think I prefer it tbh.
ImageUploadedByTapatalk1366574665.839967.jpg

Very Nice Work!

CLEAN!

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bowlofsalad   1 MW

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Re: Show Us Your Homemade Battery Housing

Post by bowlofsalad » Apr 22 2013 8:21am

Spooky1 wrote:Unfortunately the previous box was too small, I purchased the larger box from the same company, I think I prefer it tbh.
ImageUploadedByTapatalk1366574665.839967.jpg
Asthetics are one thing, function is the important detail. Why not show the inside of your pack as well? Whats the stuffing/cushion like and what is it made out of?

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jlust286   10 µW

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Re: Show Us Your Homemade Battery Housing

Post by jlust286 » Apr 25 2013 11:34pm

Here is my homemade battery box. There is a left and right side. One overlaps the other along the center to help keep water out but it will only keep light rain and mud puddle spray out.

To make this, I wrapped the frame with the batteries in plastic and clear tape. I then used about a gallon of bondo to smooth out the wrinkles and add shape to some areas. This bondo layer made the mold that was destroyed after the fiberglassing was completed. I then sanded the bondo fairly smooth and coated it with epoxy to make a hard surface. Then I applied a layer of Vaseline as my release agent and layed down 2 layers of fiberglass. After struggling to pull the hardened fiberglass shell off I then did the other side and struggled again to get the second side off. I then trimmed and sanded down all the edges and filled the low spots with bondo and sanded it smooth. The carbon fiber skin was then added by spraying both the carbon fiber and the fiberglass shell with super77 contact glue and stretching the carbon fiber over the shell. This allowed me lift and reapply the carbon fiber as needed to get the best look with one large piece of fabric for each side. Then I applied 3 coats of epoxy making sure the first coat wet out the carbon layer all the way through. Then I wet sanded it to smooth out the epoxy layer while being very careful not the sand into the carbon fiber layer. Applied the dragon decals then primer and paint. Removed the decals and applied 4 coats of automotive clear.

DRAGON BIKE 6.jpg
Batteries wrapped in plastic
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DRAGON BIKE 7.jpg
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DRAGON BIKE 8.jpg
DRAGON BIKE 8.jpg (191.56 KiB) Viewed 4838 times
DRAGON BIKE 10.jpg

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Kingfish   10 GW

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Re: Show Us Your Homemade Battery Housing

Post by Kingfish » Apr 26 2013 12:17am

^ +1: Organic & beautiful! Thank you for the inspiration 8)

How much does it weigh?
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dbaker   100 kW

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Re: Show Us Your Homemade Battery Housing

Post by dbaker » Apr 26 2013 7:59am

Well done!!

bundanoonboy   1 µW

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Re: Show Us Your Homemade Battery Housing

Post by bundanoonboy » Apr 27 2013 5:46am

most excellent work!
I never thought of doing that, I've been hand beating a sheet of aluminium for a couple of weeks in my spare time.
cheers

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atcspaul   10 W

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Re: Show Us Your Homemade Battery Housing

Post by atcspaul » May 01 2013 7:25am

awesome job! makes the bike look alot like the scwhinn home grown carbon series from years back which was an awesome bike

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spinningmagnets   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by spinningmagnets » Jul 18 2013 8:40pm

From wemadethis, retangular pack, sheet-metal raingutter? (edit: sheet-metal track for commercial building)
http://endless-sphere.com/forums/viewto ... 80#p768249

Image
Last edited by spinningmagnets on Jul 19 2013 2:12pm, edited 1 time in total.

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GCinDC   10 GW

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Re: Show Us Your Homemade Battery Housing

Post by GCinDC » Jul 18 2013 9:35pm

spinningmagnets wrote:From wemadethis, retangular pack, sheet-metal raingutter?
nope, that's steel track for steel studs normally used in commercial wall construction. it's too easy to work with, very thin, not heavy and very stiff when secured, oh, and a great width for 5s or 6s packs... i think i have photos in this thread!
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Tinto   100 W

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Re: Show Us Your Homemade Battery Housing

Post by Tinto » Jul 18 2013 10:58pm

Given it has an internal wall use, do they bother rolling the edges on that stuff?
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amberwolf   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by amberwolf » Jul 19 2013 1:35pm

Not on the stuff I have around at my house somewhere.

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veloman   1 GW

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Re: Show Us Your Homemade Battery Housing

Post by veloman » Aug 06 2013 4:52pm

Pelican 1300 case - perfect fit for 23s 1p 38120 Headway cells - IF you don't use the cell blocks, arrange them diagonally, and just use bike tube as cushion between each cell. There is room for 1, maybe 2 more cells.

Great battery box.
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migueralliart   10 kW

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Re: Show Us Your Homemade Battery Housing

Post by migueralliart » Aug 08 2013 9:40am

Forgot to post these a while ago.. anyway for the record here they are;

Image

Image

Image

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Secret1511   100 W

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Re: Show Us Your Homemade Battery Housing

Post by Secret1511 » Oct 05 2013 9:18am

Battery case build from Dibond. Dibond is a aluminium plastic sandwich. Very strong and light. :D
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Mundo   100 W

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Re: Show Us Your Homemade Battery Housing

Post by Mundo » Oct 05 2013 12:17pm

Yuba Mundo battery box..........
Attachments
battery box.jpg
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spinningmagnets   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by spinningmagnets » Oct 05 2013 9:09pm

From Dreddydave, PVC square tube. Four LiPo bricks, 12S / 10-Ah
http://endless-sphere.com/forums/viewto ... 25#p501869
Image

cero   10 mW

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Re: Show Us Your Homemade Battery Housing

Post by cero » Oct 06 2013 4:00pm

This is mine, it's made of fiberglass and painted with car paint. That metalic thing on the bottom (rear) is charging connector and at the top is inlet for motor and throtle cables.
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Tommy L   100 kW

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Re: Show Us Your Homemade Battery Housing

Post by Tommy L » Oct 09 2013 7:39am

Although this isn't my electric bike battery box, it is a "Homemade Battery Housing" as per topic ;)

T5051 TIG welded aluminum 3/16" thick..... yes yes.... overkill :roll: 8) :lol:

Tommy L sends.....Image

Image
http://www.rawvelocity.com

- 4th Hoolagan FS Mtn 9C-2810 with 128v nom 9.2ah A123 40S40P(1.2Kw) - Lyen 18Fet 4115 - 77.8kph :)
http://endless-sphere.com/forums/viewto ... =4&t=39480

- 3rd Catrike 700 Bionx PL350 Velo build
http://www.youtube.com/watch?v=rYdnkaAhVtI

- 2nd 150lbs Pusher Trailer
http://www.youtube.com/watch?v=Q1qTc4sjORY

- 1st Sears NS mtn bike - Rigid 10a drill 800rpm - 2 12v AGM - 1000 watt inverter - 600w dimmer for throttle, wicked torque!

48.2mph/77.8kph Club

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Arlo1   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by Arlo1 » Oct 09 2013 9:43am

jlust286 wrote:Here is my homemade battery box. There is a left and right side. One overlaps the other along the center to help keep water out but it will only keep light rain and mud puddle spray out.

To make this, I wrapped the frame with the batteries in plastic and clear tape. I then used about a gallon of bondo to smooth out the wrinkles and add shape to some areas. This bondo layer made the mold that was destroyed after the fiberglassing was completed. I then sanded the bondo fairly smooth and coated it with epoxy to make a hard surface. Then I applied a layer of Vaseline as my release agent and layed down 2 layers of fiberglass. After struggling to pull the hardened fiberglass shell off I then did the other side and struggled again to get the second side off. I then trimmed and sanded down all the edges and filled the low spots with bondo and sanded it smooth. The carbon fiber skin was then added by spraying both the carbon fiber and the fiberglass shell with super77 contact glue and stretching the carbon fiber over the shell. This allowed me lift and reapply the carbon fiber as needed to get the best look with one large piece of fabric for each side. Then I applied 3 coats of epoxy making sure the first coat wet out the carbon layer all the way through. Then I wet sanded it to smooth out the epoxy layer while being very careful not the sand into the carbon fiber layer. Applied the dragon decals then primer and paint. Removed the decals and applied 4 coats of automotive clear.

DRAGON BIKE 6.jpg
Good job. Be carefull most epoxy is not UV protected. But if you clear coated the whole thing then its probably ok. I just used clear Gel on my last CF build.
DRAGON BIKE 9.jpg
DRAGON BIKE 7.jpg
DRAGON BIKE 8.jpg
DRAGON BIKE 10.jpg
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spinningmagnets   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by spinningmagnets » Oct 11 2013 8:56pm


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alsmith   100 kW

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Re: Show Us Your Homemade Battery Housing

Post by alsmith » Oct 12 2013 3:26am

Mundo wrote:Yuba Mundo battery box..........
Nice idea!

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cybug   10 mW

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Re: Show Us Your Homemade Battery Housing

Post by cybug » Oct 12 2013 1:31pm

Here's a 3D printed housing for 12S2P RC Lipo :
Image
2 middle parts of the 6 parts

Image
Fitting test of parts 1,2 and 3

Image
Assembling parts 1,2,3 and 4 with acetone/ABS mix.

Image
Fitting test of main body and measuring size of top and bottom caps.

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Printing top and bottom caps.

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Fitting test of assembled housing.

Image
Image
Image
Lipos inside.

Image
Image
Image
Image
Strengthened with an alloy belt.

Image
Image
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Closed with a carbon fiber sheet.

Image
Image
3D printed body covered with "3D carbon" vynil.

Image
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SHARKBITEATTACK   10 W

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Re: Show Us Your Homemade Battery Housing

Post by SHARKBITEATTACK » Oct 12 2013 2:35pm

Mundo, that aluminum work is so clean looking. Nice work!
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spinningmagnets   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by spinningmagnets » Oct 12 2013 2:45pm

cybug, c'est magnifique! At last we are seeing 3D-printed parts for E-bikes!

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