Show Us Your Homemade Battery Housing

General Discussion about electric bicycles.
User avatar
teslanv   100 MW

100 MW
Posts: 2656
Joined: Nov 03 2013 8:42pm
Location: Bellevue, WA - USA
Contact:

Re: Show Us Your Homemade Battery Housing

Post by teslanv » Apr 06 2017 9:20pm

Image

Image

Image

Image

Image
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

User avatar
mauimart   100 W

100 W
Posts: 215
Joined: Nov 10 2009 2:08pm
Location: maui

Re: Show Us Your Homemade Battery Housing

Post by mauimart » Apr 06 2017 10:45pm

@teslanv
Hey, looks kinda like mine https://endless-sphere.com/forums/viewt ... =1&t=85489 without the screws. Are you going to cut a section out of the frame and weld it in? Did you cut the panels with a water jet? Nice.
Attachments
18650 battery V2-page-001.jpg
IMG_2.JPG
IMG_3.JPG

User avatar
teslanv   100 MW

100 MW
Posts: 2656
Joined: Nov 03 2013 8:42pm
Location: Bellevue, WA - USA
Contact:

Re: Show Us Your Homemade Battery Housing

Post by teslanv » Apr 06 2017 11:33pm

mauimart wrote:@teslanv
Hey, looks kinda like mine without the screws. Are you going to cut a section out of the frame and weld it in? Did you cut the panels with a water jet? Nice.
Yes, it will be a cut & fill job.
And yes, panels are waterjet.

Looks like you are taking it to a whole nother level, MM. :shock:
DD Hubs, Batteries, Controllers & Custom Ebikes.
http://westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

User avatar
RonnieBrowen2106   100 W

100 W
Posts: 276
Joined: Apr 10 2017 9:13am
Location: Duluth, MN

Re: Show Us Your Homemade Battery Housing

Post by RonnieBrowen2106 » Apr 26 2017 5:16pm

I want to make some custom bolt on side panels to house the battery on my electric bike. I was wondering about which material should I use. I want to use fiberglass, but I heard it is kinda heavy. I heard that stock aluminum would be better for what I am trying to do. What are your thoughts?
Attachments
Optimized-WP_20170425_17_57_55_Pro.jpg

craneplaneguy   10 kW

10 kW
Posts: 779
Joined: Nov 27 2015 9:15am
Location: S.E. Idaho USA

Re: Show Us Your Homemade Battery Housing

Post by craneplaneguy » Apr 26 2017 8:06pm

.083 aluminum

User avatar
RonnieBrowen2106   100 W

100 W
Posts: 276
Joined: Apr 10 2017 9:13am
Location: Duluth, MN

Re: Show Us Your Homemade Battery Housing

Post by RonnieBrowen2106 » Apr 27 2017 8:45am

craneplaneguy wrote:.083 aluminum
Thanks. I already have everything measured and a 1:1 stencil of the side panel created. All I need now is to figure out the material to use.

bikehedz   100 µW

100 µW
Posts: 8
Joined: Jun 15 2014 8:08am

Re: Show Us Your Homemade Battery Housing

Post by bikehedz » Aug 03 2017 1:54am

Not home made but a HPC that was sent to a MC leather repairers for a custom fit. Cost me an arm and leg but fitted 8 x 10s 5 amp lipos @ 20 amp, 75V (No longer available) in there. 600km and no complaints. Controller is in a modified rack.
Attachments
1a.jpg

bikehedz   100 µW

100 µW
Posts: 8
Joined: Jun 15 2014 8:08am

Re: Show Us Your Homemade Battery Housing

Post by bikehedz » Aug 03 2017 2:10am

more of the same
Attachments
20161213_193738 copya.jpg

Boodyhole   1 mW

1 mW
Posts: 10
Joined: Oct 21 2016 10:37am
Location: Binghamton, NY, USA

Re: Show Us Your Homemade Battery Housing

Post by Boodyhole » Aug 03 2017 3:00pm

IMG_20170729_213104.jpg
Just got this piece of shit together last weekend.

<$600 for the entire build.

User avatar
Takemehome   1 kW

1 kW
Posts: 312
Joined: Sep 30 2008 11:40pm
Location: Montreal, Qc, Canada

Re: Show Us Your Homemade Battery Housing

Post by Takemehome » Aug 03 2017 7:15pm

Boodyhole wrote:
IMG_20170729_213104.jpg
Just got this piece of shit together last weekend.

<$600 for the entire build.
Wow perfect color match between helmet and wheel. :lol:
Don't dream your life, live your dream.

Don't buy anything before visiting http://ebikes.ca

Justin, Thank you.

User avatar
Luizlife   1 mW

1 mW
Posts: 10
Joined: Aug 19 2017 4:58pm
Location: MA

Re: Show Us Your Homemade Battery Housing

Post by Luizlife » Aug 21 2017 9:48am

Thinking to maybe make a big square right in the middle of the frame.

Extended the rear frame because it was cheaper then getting the hub motor relaced to the old rim.(48v 1000w)

Whole thing so far <$250

https://ibb.co/ktCYz5
Attachments
IMAG0208.jpg
IMAG0208.jpg (35.51 KiB) Viewed 2265 times
Last edited by Luizlife on Aug 21 2017 4:44pm, edited 1 time in total.

User avatar
amberwolf   100 GW

100 GW
Posts: 25475
Joined: Aug 17 2009 6:43am
Location: Phoenix, AZ, USA, Earth, Sol, Local Bubble, Orion Arm, Milky Way, Local Group
Contact:

Re: Show Us Your Homemade Battery Housing

Post by amberwolf » Aug 21 2017 2:21pm

Please attach the image directly to the post; your link cannot be visited by my browsers.


EDIT: I see you've now attached a teeny tiny thumbnail to your post, but it is not large enough to see antyhing other than that there is a bicycle of some type in the image. :(


There is an entire thread Adding Pictures at the top of every forum's sticky list if you need help.
Last edited by amberwolf on Aug 30 2017 1:50pm, edited 2 times in total.

User avatar
alsmith   100 kW

100 kW
Posts: 1182
Joined: Dec 03 2010 7:25pm
Location: Northumberland, UK

Re: Show Us Your Homemade Battery Housing

Post by alsmith » Aug 30 2017 8:15am

bikehedz wrote:more of the same
I like your solution to protecting/waterproofing the connectors coming from the controller!

User avatar
Luizlife   1 mW

1 mW
Posts: 10
Joined: Aug 19 2017 4:58pm
Location: MA

Re: Show Us Your Homemade Battery Housing

Post by Luizlife » Sep 02 2017 12:01pm

Just how the frame looks like now
49759aabacdd62da1504361165.jpg
How to frame currently looks. I already tested it out and works like a charm..
49759aabacdd62da1504361165.jpg (43.41 KiB) Viewed 2134 times
Creating the kobalt power ebike.

User avatar
amberwolf   100 GW

100 GW
Posts: 25475
Joined: Aug 17 2009 6:43am
Location: Phoenix, AZ, USA, Earth, Sol, Local Bubble, Orion Arm, Milky Way, Local Group
Contact:

Re: Show Us Your Homemade Battery Housing

Post by amberwolf » Sep 02 2017 2:01pm

Your image is so small I can't clearly see anything in it, but it looks like your toptube is broken off of or cut away from the headtube and bent way up over the handlebars. If this is the case, you should know that now all of the weight of you (which can be multiplied many times when you hit bumps and potholes) and anything else on the bike will slam into the single weld point at the bottom bracket (pedals area), and weaken it so that it bends and breaks.

Can take a while for it to show or fail, but the frame needs that top tube for it's design.

If it's a steel frame it may happen slowly, but if it's aluminum it will happen suddenly, probably when you hit a bump, and that will break the frame in half at the pedal area. Exactly what happens during the crash after that depends on how fast you're going and the terrain you're on, and other conditions, but I don't imagine it'd be much fun.


I strongly recommend re-triangulating the frame to directly transfer the pushing forces between the top of the seattube to the top of the headtube.

User avatar
Luizlife   1 mW

1 mW
Posts: 10
Joined: Aug 19 2017 4:58pm
Location: MA

Re: Show Us Your Homemade Battery Housing

Post by Luizlife » Sep 02 2017 3:32pm

I am sorry, I'm still learning how to post pictures in here.

The top and bottom tube are all connected. I had completely removed the previous top and bottom tube to make more space for batteries and a little storage space...
Attachments
54659ab142cad2ac1504384044.jpg
I hope this made it better.
54659ab142cad2ac1504384044.jpg (152.8 KiB) Viewed 2116 times

User avatar
amberwolf   100 GW

100 GW
Posts: 25475
Joined: Aug 17 2009 6:43am
Location: Phoenix, AZ, USA, Earth, Sol, Local Bubble, Orion Arm, Milky Way, Local Group
Contact:

Re: Show Us Your Homemade Battery Housing

Post by amberwolf » Sep 03 2017 3:02am

Ok, I can see it now if I zoom in on it.

The problem is you have a parallelogram and not a triangle, so there is no strength to resist the problem I described above. It can still just collapse due to that kind of breakage.

A triangle is rigid because it can't fold, but a parallelogram (or diamond or square or rectangle, etc) *can* fold.

It might never have a problem. But if it does, you probably won't like what happens. :(


If you make a complete battery box whose side panels are fully attached on all the sides of the parallelogram it'll strengthen it considerably, but if it's left open like that it is pretty weak compared to a triangle. (that's why they use triangular segmentation in frames).


The frames that are built without them are generally made of thicker/larger tubing with greater strength than the smaller stuff, larger contact area at the welds for load transfers, etc., but they also generally weigh significantly more.


You can also use gussets at the corners of the parallelogram, but it can still break just past the end of the gussets.

User avatar
Luizlife   1 mW

1 mW
Posts: 10
Joined: Aug 19 2017 4:58pm
Location: MA

Re: Show Us Your Homemade Battery Housing

Post by Luizlife » Sep 03 2017 7:47am

Thank you for the insight. I am indeed going to build a battery box that will house 20 of the kobalt 24 volt 1.5 ah tool batteries.
Attachments
54959abf11c3321f1504440604.jpg
They can easily be upgraded to the 2 ah packs.
54959abf11c3321f1504440604.jpg (105.57 KiB) Viewed 2094 times
Creating the kobalt power ebike.

minimum   10 W

10 W
Posts: 96
Joined: Nov 10 2016 2:53pm

Re: Show Us Your Homemade Battery Housing

Post by minimum » Sep 03 2017 9:01am

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.
20170326_122135.jpg
Box test fit
20170523_170406.jpg
Mockup mounts printed with PLA (small infill) to adjust any deviation in dimension from bending and welding
20170523_170406.jpg (83.68 KiB) Viewed 2073 times
20170623_160634.jpg
Mockup mounts from PLA
20170624_174141.jpg
Battery almost complete
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 :)

20170808_210008.jpg
Bike almost complete
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.

augidog   10 W

10 W
Posts: 84
Joined: Sep 29 2012 11:49am

Re: Show Us Your Homemade Battery Housing

Post by augidog » Sep 04 2017 11:36am

....
Last edited by augidog on Jan 08 2018 3:32am, edited 1 time in total.

User avatar
Luizlife   1 mW

1 mW
Posts: 10
Joined: Aug 19 2017 4:58pm
Location: MA

Re: Show Us Your Homemade Battery Housing

Post by Luizlife » Sep 04 2017 3:27pm

augidog wrote:
s-l1601.jpg
s-l1600.jpg
IMG_20160110_113036.jpg
IMG_20160128_141726.jpg
IMG_20160324_145435.jpg
IMG_20160403_130012.jpg
IMG_20160417_172103_hdr.jpg
Hybrid. Awesome !!

Pedals/gas/and electric!!
Creating the kobalt power ebike.

craneplaneguy   10 kW

10 kW
Posts: 779
Joined: Nov 27 2015 9:15am
Location: S.E. Idaho USA

Re: Show Us Your Homemade Battery Housing

Post by craneplaneguy » Sep 04 2017 5:53pm

I like the way you fit that in the frame, that's thinking outside the box. Sorry.

augidog   10 W

10 W
Posts: 84
Joined: Sep 29 2012 11:49am

Re: Show Us Your Homemade Battery Housing

Post by augidog » Sep 05 2017 9:40pm

....
Last edited by augidog on Jan 08 2018 3:32am, edited 1 time in total.

whereswally606   100 kW

100 kW
Posts: 1106
Joined: Jun 19 2011 2:11pm
Location: Cheshire, UK

Re: Show Us Your Homemade Battery Housing

Post by whereswally606 » Sep 06 2017 3:15am

A really neat build, smart too. I wonder what the range is? The motorcycle fairing on the bars seems a bit daft though. Well done.

Sent from my ALE-L02 using Tapatalk
Distributing "Lebowski" FOC Controller PCB (Through hole) since 2016
Moped: Emax 110s 2009

augidog   10 W

10 W
Posts: 84
Joined: Sep 29 2012 11:49am

Re: Show Us Your Homemade Battery Housing

Post by augidog » Sep 06 2017 8:29am

....
Last edited by augidog on Jan 08 2018 3:32am, edited 2 times in total.

Post Reply