Custom battery box for old but low mileage Scott Voltage MX5:
16S12P of Samsung 35E (~40AH)
Box made of 2mm EN AW-5754 aluminum, MIG welded together. Painted using 2-component car-paint/lacquer.
Battery with mounts designed to fit the bike without any modification to the frame (no extra holes or welds).
Mounts 3D printed from PETG.
Parallel connections welded with 12x0,2mm nickel strips, series connections soldered with 1x10mm copper (2 of them parallel). Copper strips had holes drilled in place of solder-joints for easier soldering and sort-of quality control for these joints.
Battery was cast inside the box using 2-component silicone with 37 Shore-A hardness (that's about soft pencil eraser). About 1,5kg of it was used.
BMS on the left side, mounted using thermal tape straight to aluminum for better cooling. Below under aluminum separator on the left is 100A current sensor (Allegro ACS758 based) and on the right fuse socket. DS18B20+ 1-wire temperature sensor is stuck between cells.
While designing I was intending to fit controller (without it's shell) inside that place under separator. It was overly optimistic of me - on computer screen everything seems easier
Still left to do: dashboard that would display voltage, temp, current and so on. New CNC-milled endcaps for controller for better connector and wiring handling along with proper fixings to battery mounts.